Lost-foam casting represents one of the revolutionary metal casting processes to have advanced manufacturing in various industries. The process is known for offering unparalleled precision, cost efficiency, and eco-friendliness; hence, EPC is applied to the manufacturing of complex and detailed metal components. From basic concepts and various applications, to some of the unique benefits this technique offers, along with Hangzhou Ouchen Technology Co., Ltd. at the forefront of developing this highly innovative process. What is Lost-Foam Casting, and How Does it Work?Lost-foam casting is a manufacturing process where molten metal replaces a pattern of foam to produce metal castings with great detail. There is no need to use the traditional sand core or any complicated mold, making lost-foam casting among the most efficient and modern casting techniques. Step-by-Step Lost-Foam Casting ProcessPattern DesignIt starts with a foam model, which is normally made from expanded polystyrene or other similar materials. The models can be hand-cut, CNC-machined, or mass-produced using molds, depending on the complexity and scale of production. Refractory Coating ApplicationThe foam pattern is coated with a refractory material to improve surface finish and prevent erosion during the pouring of metal. It is also referred to as mold and core coating. Mold AssemblyThe coated foam pattern is buried in unbonded sand inside a mold container. The sand keeps it stable and ensures that the molten metal reproduces the shape of the foam model accurately.Metal PouringIn the process, liquid metal is allowed to pour inside the mold. While falling in the cavity, it vaporizes the foam pattern into the perfect geometry one wishes for the component required.Cooling and Extraction After cooling down, the molten metal turns into final casting. Later, the mold made of sand is knocked, and the metal casting undergoes whatever finishing touches are required to them.