As a professional lost foam casting manufacturer, we provide one-stop lost foam casting services covering foam pattern making, refractory coating, sand filling, metal pouring, and precision finishing. Lost foam casting is ideal for complex, near net shape components with excellent dimensional accuracy and smooth surfaces, reducing machining costs and improving efficiency. Our lost foam casting solutions are widely used in automotive parts such as engine blocks and manifolds, as well as pumps, valves, and construction machinery, making us a trusted supplier for high-precision and cost-effective metal castings.
The Lost Foam Casting process includes making a foam pattern, coating it with refractory material, pouring metal, letting it solidify, and then removing the foam and cleaning the casting.
In lost-foam casting, foam patterns mimic the precise geometry of the finished metal object. The gating system has passages that direct molten metal into the mold and may be integrated into the foam pattern or attached (glued on) later. These passages enable precise designs and streamlined metal flow, resulting in castings that are accurate and effective.
Tightly bind the foam patterns and gating mechanisms to form the mold bundle module prior to casting. This assembly makes the casting process easier by ensuring precise component alignment, reducing mistakes, and facilitating reliable, consistent manufacture of complex metal parts.
An application of refractory dip paint follows the assembly of the mold bundle module. When this paint dries, it creates a protective ceramic coating that improves the mold's surface toughness, heat resistance, and capacity to handle the temperature and pressure of the molten metal.
Coat the mold bundle module, set it within a molding flask, and cover it in dry sand. This phase ensures accurate replication of the desired metal part by supporting the module's shape, keeping it in place during casting, and facilitating uniform sand compaction.
Sand may now flow into every nook and cranny of the mold bundle module thanks to vibrations imparted to the molding flask. Through careful sand compaction and the elimination of air spaces, this procedure enables the creation of a high-quality casting with exact measurements and fine details.
Carefully pour the molten metal into the mold, replacing the vaporized foam patterns. The metal solidifies to create the desired casting as it fills the spaces the foam left behind. As a result, the finished product closely resembles the planned form while minimizing flaws and blemishes. This technique supports complicated and complex shapes.
After the castings have cooled and set, clean the casting to get rid of any remaining sand, ceramic shells, and other impurities. To produce high-quality and aesthetically pleasing metal parts, this phase means that the final castings fulfill quality requirements, have smooth surfaces, and are ready for subsequent finishing procedures or assembly.
High-quality materials tailored for diverse casting applications
In Lost Foam Casting (LFC), stainless steel can be used to produce high-complexity, near-net-shape corrosion-resistant parts. With refractory coating on the foam pattern and vacuum dry sand molding, it reduces machining requirements while ensuring good surface quality and dimensional stability.
Alloy steel in Lost Foam Casting offers high strength and wear resistance through adjustable composition and heat treatment. LFC eliminates traditional draft and mold-parting restrictions, making it suitable for highly loaded and complex-shaped components.
Carbon steel is one of the most widely used materials in Lost Foam Casting. It offers low cost and high strength, while LFC enables efficient production of complex structural and general mechanical components.
Relying on powerful and matchless machining finish capabilities, our company expand the product lines and is committed to manufacturing and supplying iron and steel castings made by various casting methods, forgings and profile machined parts.
Get a Quote| Item | Description |
|---|---|
| Material Standard: | GB.ASTM.AISI.DIN.BS.JIS.EN.AS.AAR. |
| Max linear Size(W*C*H): | 1500mm*800mm*750mm |
| Min thickness: | 6mm |
| Casting Weight Range: | 1-500kgs |
| Casting Dimension Tolerance: | CT6-8 |
| Casting Surface Roughness: | Ra12.5um |
Qianhao Group offers tailored shell molding casting solutions to meet diverse requirements, providing one-stop services from mold preparation to precision finishing.
For Lost Foam Casting (LFC) orders we offer fast turnaround: small batches can be delivered in 15 days, large production runs in 30 days, and urgent orders can be expedited so you meet critical project deadlines.
We provide end-to-end Lost Foam Casting services — from foam pattern design and assembly, through refractory coating and packing, to metal pouring, heat treatment and precision finishing — ensuring repeatable quality for complex castings.
Our Lost Foam Casting capability delivers high-precision tolerances (typical achievable tolerances down to ±0.1mm depending on design and finishing), making LFC ideal for aerospace, medical, automotive and industrial parts with complex geometry.
Qianhao is a globally recognized manufacturer of high-valued added and complex castings for global industry leaders