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Lost Foam Casting

Lost foam casting continues to grow in popularity among casting companies because it enables them to produce near-net-shaped components of high complexity with thin walls and other fine-scale features, parts that require fewer gaskets to assemble. And, since there is little need to use binders in the sand, the sand used for their molds can be re-used, saving more money

For the process to be successful there must be a high degree of control. To help casters address some of these difficult problems, FLOW-3D Cast has special models to simulate the lost foam process. With these models, a user can simulate the filling of a lost foam mold as well as the subsequent solidification of the metal. More importantly, FLOW-3D Cast allows the user to predict where folds or other defects associated with trapped foam products are likely to be located.

Lost Foam Simulation by BMW