Lost Foam Casting

Lost Foam Casting is an evaporative-pattern casting process that utilizes an expanded polystyrene (EPS) foam pattern to produce highly complex, precise metal components. First, a foam replica of the desired part is molded or carved, coated with a heat-resistant refractory layer, and placed inside a casting flask surrounded by un-bonded, compacted sand for support.

At Mahadev Ferro Cast Pvt. Ltd., our Lost Foam Casting process enables the production of complex Grey Iron and Ductile Iron components with excellent dimensional accuracy, design flexibility and reduced machining requirements.

Our Facilities Specs

Capacity

1,000 MT/month production.

Vacuum System

Centralized-decentralized setup for efficiency.

Manpower

Fully operated with 30 people.

Automation

100% robotic casting chamber handling.

Workplace

Clean, dust-free environment.

Why Choose Lost Foam Casting

Reduced Porosity & Inclusions

Minimized Gas Entrapment & Inclusions

Lost foam refractory coatings are designed with high permeability, allowing gases to escape freely. Since the sand used contains no binders or resins, gas evacuation is further facilitated.

Artificial Ceramic Sand High Permeability

Mahadev utilizes engineered ceramic sand with excellent permeability, enabling efficient gas dissipation during pouring.

What Lost Foam Casting is?

Thin-Walled Sections

The process supports thin-walled designs, reducing material usage and weight.

Intricate Shapes & Complex Geometries

Lost foam casting allows for the production of highly complex and detailed castings without the need for cores.

Near-Net Shape Casting

Reduces the need for machining and post-processing, minimizing waste.

No Parting Lines or Core Shift Issues:

Eliminates the need for multiple core assemblies, reducing defects and simplifying mold setup.

Consistent & Repeatable Quality:

Ensures dimensional accuracy and uniformity in large production runs.