Lost Foam Tooling
Versevo designs and manufactures lost foam tooling and glue fixture tooling used for the casting industry. Our sales, engineering professionals, and tool makers are state certified journeymen with decades of experience in the lost foam industry and can answer all of your tooling, casting, and production machining questions. From your project's initial startup to machined castings ready for assembly— let the Versevo team deliver your turn-key lost foam tooling solution.
Lost Foam Tooling & Casting Process
- A pattern of the part is made from expanded polystyrene foam beads. These beads are first pre-expanded and then stabilized, after which, they are blown into a tooling mold to form the pattern shape used during the casting process. A steam injection cycle then causes these beads to expand further, fuse together, and finally the foam pattern undergoes a cooling cycle within the lost foam tooling mold. If the final casting part shape is too complex for a single mold, then several sub-sections of these patterns can be molded and combined using additional lost foam tools for each cavity and separate glue fixture tooling.
- Once the complete moldable foam pattern is complete, several of these foam parts can be glued to a foam gating system to complete a casting cluster. The foam gating system is formed using the same procedure as the pattern parts.
- In the next step, the foam cluster is coated with a ceramic material, also known as refractory coating, by brushing, dipping, spraying or by flow coating. This ceramic coating creates a barrier between the foam parts surface and the mold's sand surface. This coating also controls permeability, which allows the gas created by the vaporized foam to escape through the coating into the sand mold. This coating also foams a barrier so the molten metal does not penetrate the sand cavity and further prevents sand erosion during pouring.
- After the ceramic coating process, the coated foam cluster is aged and then placed into a flask. The flask is then filled with unbonded sand and then compacted using a vibration table. Once the sand has finished compaction the mold is ready to be poured.
- Finally, molten metal is poured into the lost foam cavity, the foam vaporizes, and is replaced by the molten metal. Vents in the side of the flask allow vapors to escape. Once the molten metal cools and solidifies, the sand and ceramic material is then removed revealing the casting.
Lost Foam Tooling & Casting Advantages
- Simple to Complex Castings
- Ability to Combined and Eliminate Multiple Casting Parts
- Easy to Mold, Carve, and Glue
- Excellent Casting Finish
- Extremely Accurate Dimensional Tolerances
- Minimal Production Machining
- Recreation (RV, ATV, Watercraft)
- Ductile Iron
Lost Foam History
Lost Foam casting was invented in 1964 by M.C. Flemmings. Public recognition of the benefits of Lost Foam casting was made by General Motors in the mid 1980s when it announced its new car line, Saturn, would utilize Lost Foam casting for production of all engine blocks, cylinder heads, crankshafts, differential carriers, and transmission cases.
Versevo's sales, engineering, and tool makers have decades of combined experience in Lost Foam tooling development and casting. From your project's infant stages — 3D part modeling phase and tooling design phase, through tool manufacturing and production machining resulting in a 100% finished product ready for your assembly line — we can provide you a complete end-to-end manufacturing solution.