The basic steps of the lost foam casting process are:
1. Pattern molding
Production of patterns in a precision tool with expendable polystyrene (EPS) beads (Heat expands and bonds the beads to produce a rigid pattern).
2. Cluster assembly
Assembly of the patterns onto a gating system.
Coating the pattern assembly with a refractory wash coat.
4. Sand fill and compaction
Forming the mold by compacting dry sand around the coated pattern in a one piece flask.
5. Casting four
Pouring the metal into the mold with vaporization of the EPS pattern.
Shakeout, cut off, finishing, and inspection of the casting.
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