Lost Foam Casting

Certified top quality production in Europe and Asia

INTEGRAL SOLUTIONS

Over the years, our experienced team has proven its worth by offering the best expertise and know-how in its field

Gamarra casting solutions

your one-stop-shop

lost foam casting solutions; covering all the manufacturing process, from design, patterns and casting to machining and finishing

Gamarra quality

Best Quality STANDARDS

All our products and processes are submitted to the most stringent internal and external quality, safety and environmental controls

corporate responsibility
CORPORATE RESPONSIBILITY

Our corporate strategy addresses the global challenges we face; including inequality, climate, environmental degradation, prosperity and justice

MATERIALS AND DIMENSIONS

We produce cast steel with an extensive range of physical properties. Offering both automatic and manual molding operations up to 2000 kg and max size 2000 x 1500 x 15000 with carbon steel castings and different alloys:

Alloy Steel
Low alloy steel
Carbon Steel

Our LOST FOAM Casting Production Process

A multi-step process that produces near-net shape precision casting parts. The process begins with the creation of patterns. These are then used to create moulds that are filled with molten metal to create the part. Secondary processing, such as machining, welding or painting can also be done. The process uses different machines such as furnace, injection, blasting, tumbling, cutting, grinding, etc. The process involves mainly the following steps

1. Pattern Design​​

Designing patterns is a complex process that requires very specific know-how

2. Pattern Making​​

Patterns made of wood, resin (plastic) or aluminium could be used to produce during the casting

3. Molding Process

Moulds are created with sand that is pressed using the pattern to create the desired shape

4. Melting

Electrical furnaces are used to melt iron from scrap and the necessary alloys or additional components needed to achieve the desired final standard

5. Pouring and solification

Liquid steel is then poured into the moulds and left until it solidifies.

6. Sawing or Cutting

Once the metal has cooled and solidified, the cast part(s) is then removed from the mould via shaking, cutting or friction sawing off the individual cast part

7. Shot Blasting and Secondary Processing

The parts are blasted to fully remove the sand and oxides. The casting part is then fully customized through grinding or additional heat treatments

8. Testing, Packing and Delivery

Then the casting parts will be fully tested for the dimensions, surface, mechanical properties and other required tests before packing and delivery

Want to know more of Lost foam casting

A variation of the investment casting process, the pattern in lost foam casting is made of expanded polystyrene, dipped (invested) in a ceramic shell. Design flexibility is a key feature of this process, which lends itself to large castings, complex shapes and low part numbers.

 Pre-forms of the parts to be cast are molded in expanded polystyrene (or other expandable polymers) using aluminium tooling. Gluing EPS moldings together can form complex shapes. The pre-forms are assembled into a cluster around a sprue then coated with a refractory paint. The cluster is invested in dry sand in a simple molding box and the sand compacted by vibration. Metal is poured, vaporising the EPS pre-form and replacing it to form the casting.

EBU.Foam Facility
EBU.Foam Facility Principal

Industries and applications for lost foam casting

Our lost foam casting services are present in a wide variety of products, including high quality, top performance industrial parts. We typically serve the following industries:

Our quality assurance services and processes ensure product reliability and customer satisfaction

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