The Lost Foam Casting process (LFC) is the process that uses foamed polymer models to represent
the casting and parts of the gating system. Because the polymer models are destroyed during
this process, you will also find the term Expendable Pattern Casting (EPC) or the German term
Vollformgießen.
Within the Lost Foam Casting process, the models are typically made of foamed expandable polystyrol
(EPS), of foamed expandable polymethylmethacrylat (PMMA) or of a foamed co-polymer of
EPS and PMMA. The models are created in permanent molds on automatic foaming machines,
with a predefined thickness. By glueing simple models together, model segments are then combined
to complex models. After that, several models are often combined to model trees. After attaching
the gating system, the model is coated by a fire resistant, anorganic coating and
embedded into compressed sand that is free from binding agents.
Within the actual casting process, the metal melt replaces the polymer model.
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