Lost Foam Casting

  • OEM Services
    Metal Bending Deep Drawing Metal Cutting Metal Welding
    Hot Die Forging Cold Forging Open Die Forging Seamless Ring Forging
    Sand Casting Investment Casting Die Casting Gravity Casting Lost Foam Casting
    Metal Bending

    Metal Bending

    FLUIDO provides professional metal stamping services for manufacturing a wide range of custom parts with precision and consistency. From simple brackets to complex stamped components, we offer cost-effective production solutions based on your drawings and specifications. With advanced equipment, experienced technicians, and strict quality control, we ensure reliable quality, fast turnaround, and competitive pricing for every project.

    Deep Drawing

    Deep Drawing

    FLUIDO specializes in deep drawn stamping services for producing seamless, high-strength metal components with complex shapes. Our advanced forming capabilities allow efficient production of cups, housings, covers, and other deep-drawn parts with excellent dimensional accuracy and surface quality. We support both prototype development and high-volume manufacturing.

    Metal Cutting

    Metal Cutting

    FLUIDO provides precision metal cutting services for carbon steel, stainless steel, aluminum, and other materials. Utilizing advanced cutting technologies and experienced operators, we deliver clean edges, accurate dimensions, and high production efficiency. We ensure reliable results that meet your specifications.

    Metal Welding

    Metal Welding

    FLUIDO delivers professional metal welding services for custom fabricated components and assemblies. Our skilled welding team works with various materials and welding processes to ensure strong joints, structural integrity, and consistent quality. From small parts to large fabricated structures, we provide dependable welding solutions tailored to your project needs.

    Hot Die Forging

    Hot Die Forging

    FLUIDO offers hot forging services for producing complex and high-strength metal parts. By shaping heated metal under controlled conditions, we achieve excellent material flow, improved grain structure, and enhanced mechanical performance.

    Cold Forging

    Cold Forging

    FLUIDO provides precision cold forging solutions for components requiring tight tolerances and excellent surface finishes. This process improves material strength while minimizing machining requirements and material waste.

    Open Die Forging

    Open Die Forging

    FLUIDO specializes in open die forging for large and custom-shaped components. This process provides superior strength, structural integrity, and flexibility for producing shafts, blocks, discs, and other heavy-duty forged parts.

    Seamless Ring Forging

    Seamless Ring Forging

    FLUIDO manufactures seamless rolled rings with excellent strength, dimensional accuracy, and material consistency. These forged rings are widely used in valves, bearings, flanges, gears, energy equipment, and other demanding industrial applications.

    Sand Casting

    Sand Casting

    FLUIDO provides sand casting solutions for small to large metal components with flexible designs and cost-effective production. Sand casting is suitable for a wide range of materials and applications, especially medium- and large-sized parts.

    Investment Casting

    Investment Casting

    FLUIDO offers investment casting services for precision components requiring complex geometries, tight tolerances, and superior surface finishes. This process is widely used for valves, pumps, machinery parts, and other high-performance applications.

    Die Casting

    Die Casting

    FLUIDO offers precision die casting services for producing high-volume metal parts with excellent dimensional accuracy and surface finish. This process is ideal for complex components that require consistency, efficiency, and minimal post-processing.

    Gravity Casting

    Gravity Casting

    FLUIDO delivers gravity casting services for manufacturing durable components with improved mechanical properties and reduced porosity. This process provides excellent dimensional stability and surface quality for various industrial applications.

    Lost Foam Casting

    Lost Foam Casting

    FLUIDO specializes in lost foam casting for producing complex metal parts with minimal machining requirements. The process enables intricate shapes, high design flexibility, and efficient production of near-net-shape components.

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Lost Foam Casting

Lost Foam Casting

What Is Lost Foam Casting?

Lost foam casting is a metal casting process that uses a foam pattern to create complex metal parts with high dimensional accuracy. In this process, an expanded polystyrene (EPS) foam model is made in the exact shape of the final product. The foam pattern is coated with a refractory coating, buried in dry sand, and then filled with molten metal. As the metal enters the mold, the foam evaporates and is replaced by metal, forming the final casting.

This process is ideal for producing complex shapes, thin-wall components, and near-net-shape parts with fewer machining requirements. Lost foam casting is widely used for automotive components, pump housings, valve bodies, machinery parts, and other precision metal products.

Our Lost Foam Casting Capabilities

Material

Ductile Iron, Gray Iron, Malleable Iron, Carbon Steel, Stainless Steel, Aluminum and Its Alloy

Tolerance

±0.05 mm

Casting Weight

0.1kg-500kg

Maximum Outline Dimension

Up to 1200 mm

OEM & ODM

Supported

Finishing

Heat Treatment, CNC Machining, Surface Treatment

Manufacturing

According to to the drawings or samples


Our Lost Foam Casting Capabilities

1. Foam Pattern Production

We create EPS foam patterns based on your drawings or samples. The foam pattern is manufactured to match the final casting geometry, including runners and gating systems.

 

2. Pattern Assembly

Multiple foam patterns are bonded together to form a complete casting cluster. This improves production efficiency and ensures stable metal flow during pouring.

 

3. Refractory Coating

The foam assembly is coated with a refractory ceramic layer and fully dried. The coating improves surface finish, controls gas escape, and protects the mold during pouring.

 

4. Sand Filling and Vibration

The coated foam pattern is placed into a flask and surrounded with dry unbonded sand. Vibration compacts the sand evenly around the pattern to maintain accurate dimensions.

 

5. Molten Metal Pouring

Molten metal is poured directly into the mold. The foam pattern instantly vaporizes under high temperature, while the metal fills the cavity and forms the desired casting shape.

 

6. Cooling and Shakeout

After solidification and cooling, the sand is removed and recycled. The raw casting is separated from the gating system for further processing.

 

7. Finishing and Inspection

We provide cleaning, grinding, machining, heat treatment, surface treatment, and dimensional inspection to ensure every casting meets your specifications and quality requirements.