Process: Foam pattern made from polystyrene foam in a steel die. Patterns assembled on a sprue, coated with refractory material then placed in a metal flask, surrounded by compacted sand. Molten metal poured into mold dissolving foam pattern, creating the casting. After solidification, castings are cleaned and ready for use.

• Size Range: 1 Lb. To 500 Lbs.
• Normal Lead Times- Samples: 6-10 Weeks
• Production: 4-6 Weeks
• Materials Available: Iron and aluminum.

Advantages:

• Nearly unlimited design freedom.
• No cores needed.
• 1 degree of draft or less.
• Can cast many features and reduce machining costs.
• Good directional solidification means full grain structure and good casting integrity.
• Good for complex parts.
• Tolerance up to + - .005

Disadvantages:

• Higher tooling cost.
• Glue line witness.