Lost foam casting forms complex components without traditional parting lines or multiple cores. It is used when conventional sand casting would otherwise require several cores or significant post-cast machining
Eliminates traditional parting lines
Reduces the number of internal cores required
Simplifies mould assembly for complex geometries
Can reduce grinding and secondary machining
Lost foam casting uses a foam pattern that matches the final component geometry. The pattern is placed in sand without splitting the mould along a traditional parting line.
When molten metal is poured, the foam vaporises and is replaced by metal, forming the complete shape.
Because the geometry is created from a single pattern rather than multiple mould sections and cores, mould assembly is simplified and variation introduced by core setup is reduced.
Lost foam casting is used for components where internal geometry or assembly complexity would make conventional sand moulds difficult to manage.
Lost foam casting can be applied to a range of ferrous and non-ferrous alloys, depending on geometry, service conditions, and mechanical requirements.
Selected for strength combined with toughness and wear resistance.
Used where strength, weldability, and structural performance are required.
Applied where enhanced mechanical performance or heat resistance is needed.
Used in environments requiring corrosion resistance alongside structural integrity.
With four generations of casting heritage and fully integrated capabilities, Milson gives OEMs confidence that every sand casting will be production-ready, consistent, and dependable in the field.
If you are developing a new part or troubleshooting production, our engineers provide clear guidance, fast feedback, and practical solutions.
