Lost Foam Technology The lost foam process starts as pre-expanded polystyrene beads are blown into a mold in order to form foam patterns. After an aging process for foam stabilization, the patterns are glued to a downsprue forming a cluster.
The cluster is then dipped into a ceramic coating. The coating acts as a barrier between the sand and molten metal and also acts as a control for the metal flow rate.
After a specified drying period, the coated cluster is then placed in a flask and packed with loose sand. The flask then undergoes a compaction cycle in which the sand is vibrated into all open cavities in the cluster.
Finally, molten metal is poured into the flask vaporizing the foam. The result is a casting which replicates the foam pattern.
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Lost Foam Benefits
Design Flexibility - Lost Foam technology offers flexibility which allows for the consolidation of two or more parts into one component.
Elimination of Cores - This design advantage allows for more complex designs and produces more consistent wall thickness.
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Machining and Weight Reduction - Because Lost Foam requires less draft (0-2°) than traditional methods, machine stock can be reduced. Other advantages, such as the ability to cast holes to tight tolerances (±.005), can eliminate machining operations.
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Other Lost Foam Benefits -
- Dimensional Accuracy
- Improved Surface Finish
- Increased tool life (100,000 - 500,000 cycles)
- Elimination of parting lines
- Cast-in inserts
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