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Lost Foam Metal Casting Technology by Jayshree Machines And Tools
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Lost Wax Versus foamcast Lost Foam Metal Casting Technology

PropertyLost Wax ProcessFoamcast Lost Foam Metal Casting Technology
Composition of PatternMicrocrystalline WaxExpanded Polystyrene (EPS)
Density of Material used for patternDensity of Microcrystalline Wax Patterns - 795 kgs./m³, resulting in heavy delicate patterns.Density of Expanded Polystyrene Patterns - 42 kgs./m³ sufficient for strong, sturdy, dimensionally accurate and light patterns.
Maximum Size of Cast PartApprox. 200-300mmNo limitation of size for cast part as EPS Pattern can be molded in sections and finally assembled to form a single pattern.
Maximum Weight of Cast PartWell Below 125 kgs.No limitation of weight of cast part.
Rejection of Shell during processThe ceramic shell has a tendency to crack during the autoclave process due to the expansion of WaxThe ceramic shell does not crack during the burn-off process as EPS does not expand but evaporates/melts.
Pre-Heating of Ceramic ShellRequiredNo required, pouring is possible at room temperature of ceramic shell.
MethodingDifficult and has limitations in addition to the problem of riser backfilling.Flexible, risers are simply glued on the pattern to suit the methoding. Furthermore the feeding ability of riser is improved with the use of exothermic sleeves.
Ceramic Shell ThicknessApprox. 10-15mmApprox. 5-10mm depending on the size of component.
Pattern/Casting PrototypingDifficultEasily possible as EPS foam can be machined and assembled to form patterns
Effect of atmospheric heat on patternsPossibility of Wax pattern to warp or bend.No effect on EPS pattern once cooled in the molding tool.

Process Video
Process Presenation
Process Cost
Equipment
V/s Sand Casting
V/s Green Sand
V/s Chinese Process
V/s No Bake
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