Lost Foam Casting (LFC): Lower Lead Time and Increased Capabilities

The quickest, most efficient, and cheapest method for producing large metal components is casting. Now with recent developments in lost foam casting (LFC), also known as expendable pattern casting (EPC), it is possible for design engineers to obtain cast iron, steel, and nonferrous castings in as little as five days with as-cast tolerances of +/-0.003 inch/inch. This paper outlines the steps to having decreased lead time and focuses on the actual requirements for the lost foam process from a design perspective. It includes examples of how standard casting design rules do not hold, e.g. parting lines, use of draft, and interlocking components. It also explores the latest research, including thin-walled ductile iron and surface-alloyed cast components. Practical case studies and examples are included. Presented at: Rapid 2010 and 3D Imaging Conferences & Exposition, Society of Manufacturing Engineers, May 18-20, 2010, Anaheim, CA.