Full Mold Casting

Full Mold CastingFull-mold casting technique is quite similar to investment casting, but here polystyrene foam is used as the pattern. The foam pattern is laced with a refractory material. The pattern is put in an encasing of one-piece sand mold, during the pouring of the metal. The foam vaporizes and its place is taken by the metal.

Features
  • Complex shaped castings: Possible without any draft or flash.
  • Minimum wall thicknesses: 2.5 mm
  • Tolerances: Can be held to 3% on dimensions.
  • Surface finish: From 2.5µm to 25µm (0.1µin to 1.0 µin) rms.
  • Size limits: From 400 g (1 lb) to several tons.
  • Draft allowance: Required.
Application of Full Mold Casting: Materials cast with this process are aluminum, iron, steels, nickel alloys, copper alloys to produce pump housings, manifolds, and auto brake components.
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