Lost Foam Casting Parts

GooCasting® specializes in custom lost foam casting (EPC – Expanded Polystyrene Coating) parts for automotive, pump, valve, and machinery industries. Our advanced lost foam casting process produces complex geometries with excellent surface finish and dimensional accuracy.

What is Lost Foam Casting?

Lost foam casting, also known as EPC (Expanded Polystyrene Coating) or evaporative pattern casting, is an advanced casting process that uses a foam pattern which evaporates when molten metal is poured into the mold. This process eliminates the need for parting lines and cores, allowing for complex geometries and superior surface finish.

Our Lost Foam Casting Capabilities

• Materials: Gray Iron (HT200, HT250, HT300), Ductile Iron (QT400, QT450, QT500), Carbon Steel, Alloy Steel, Aluminum
• Weight Range: 0.5 kg to 500 kg
• Tolerance: IT9-IT12 (near-net shape)
• Surface Finish: Ra 3.2-12.5 μm (as-cast)
• Minimum Wall Thickness: 3mm
• Production Capacity: 200 tons/month

Advantages of Lost Foam Casting

• ✓ Complex Geometries: No parting lines, no cores required
• ✓ Excellent Surface Finish: Ra 3.2-12.5 μm reduces machining
• ✓ Dimensional Accuracy: IT9-IT12 tolerance
• ✓ Design Flexibility: Internal passages, undercuts, complex shapes
• ✓ Cost-Effective: Reduced machining, lower tooling cost
• ✓ Environmentally Friendly: Minimal waste, recyclable materials

Applications

Our lost foam casting components are widely used in:

• Automotive: Engine manifolds, cylinder heads, brake components, transmission cases
• Pump & Valve: Complex pump housings, valve bodies with internal passages
• Machinery: Gearbox housings, motor frames, complex brackets
• Heat Exchangers: Complex cooling passages, manifolds
• Marine: Propeller hubs, marine engine components
• Aerospace: Lightweight structural components, housings

Why Choose GooCasting® for Lost Foam Casting?

• ✓ Advanced EPC Process: Automated foam pattern production
• ✓ In-house Foam Pattern Making: Fast prototyping and tooling
• ✓ Complete Quality Control: X-ray, pressure testing, CMM inspection
• ✓ Engineering Support: DFM analysis, design optimization
• ✓ Competitive Pricing: Direct factory pricing
• ✓ Fast Lead Time: 15-25 days for samples, 30-45 days for production

Request a free quote for your lost foam casting project today!