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Lost Foam

General Aluminum Manufacturing Lost Foam ProcessThe Lost Foam process uses polystyrene patterns that are built into clusters of one to several patterns per cluster. These clusters are coated and then compacted into a metal flask. When molten Aluminum is introduced it displaces the polystyrene pattern precisely duplicating all of the features. A polystyrene pattern must be produced for every casting that is poured. This process allows for highly complex parts to be produced to very tight tolerances. Often times multiple components can be produced as a single piece with no secondary operations required. Typical applications include Pumps, Adaptors, and Housings.