Lost foam castings are metal castings or components made or produced by creating a styrofoam replica / pattern and pouring molten metal over it to create a finished part. Lost foam castings are used by manufacturers to build engines, equipment, gas nozzles, electronics enclosures, and railroad car components.

Companies that use aluminum components in their manufacturing process use lost foam castings. The industries that use lost foam castings include engine manufacturing, automotive, electronics, and recreational vehicle manufacturing companies.

Lost foam is Willard Industries' niche market. Very few companies use the lost foam casting method to produce castings. Willard is one of the few "jobbing" foundries that manufacture lost foam parts.

One benefit of lost foam castings is design flexibility. Lost foam technology offers flexibility which allows for the consolidation of two or more parts into one component.

Another benefit of lost foam castings is the elimination of cores. This design advantage allows for more complex designs and produces more consistent wall thickness.

Lost foam castings also help with machining and weight reduction. Because lost foam requires less draft (0-2°) than traditional methods, machine stock can be reduced. Other advantages of lost foam, such as the ability to cast holes to tight tolerances (±.005), can eliminate machining operations.

Some other lost foam benefits include dimensional accuracy, improved surface finish, increased tool life, elimination of parting lines, and cast-in inserts.