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Lostfoam Casting Process - Questions and Design Criteria

What type of tooling is needed? How much will the tooling cost?

Typically a split cavity aluminum die is made that is the negative mold from which the positive foam pattern is produced. This tooling is highly specialized and must be done by expert tooling manufacturers familiar with the requirements of the casting producers. "The casting can be no better than the pattern used to produce it." Most tooling for Lost Foam patterns will compare very favorably with permanent mold and die casting. About $1000 on the low end to several hundred thousand dollars on the high end for automotive components like engine blocks, cylinder heads, and manifold. Lost foam tooling life is at least 5 to 6 times that of permanent mold or die cast tooling.

One of many Major advancements of Prototyping parts, before hard tooling is cut, casting shrinkage can be established. This can get a project on track, many months ahead of schedule of permanent hard tooling. Process Parameters can also be worked on, during permanent tool construction, saving time for casting development. Rapid Prototyping in Lost Foam can be done by MACHINE CUT FOAM, CNC CUT FOAM, SPRAY METAL TOOLING, OR EVEN SPECIAL EPOXY TOOLING. Another advantage of prototyping is having the capability of testing out a specific design, before spending on tooling. Customers have cut years off development on this type of prototyping development.

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