Custom Lost Foam Casting Supplier
Lost foam casting is a process used to create complex metal pieces and parts in which molten metal evaporates a foam mold being held still with sand. The process starts with a polystyrene foam as the mold material which can be carved, machined from a foam block, or created using a process similar to injection molding.
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The latter process uses beads of polystyrene that are heated inside an aluminum die to expand and fill the die. A completed polystyrene foam mold is then covered with a ceramic refractory coating to create a barrier between the foam and the sand in which the foam mold sits. The small amount of waste gas created can escape into the sand.
Advantages/Disadvantages
There are many advantages to rapid prototype casting. There is a reduced cost and lead time to create a part. There is little to no machining needed and there is a high level of design freedom. Incredibly complex shapes can be created with various characteristics that are difficult to achieve with other methods. An example is parts with thin walls.
The finished metal parts have a nice surface finish. A large disadvantage can be the time it takes to create a CAD design as well as the level of expertise it requires. Part sizes are also limited to the size of the printing area in the machine creating them. The metals that finished parts can be created in is limited by metals with a lower melting point.
Applications
Rapid prototype casting is used in a variety of industries including the arts, computer technology, agriculture, national defense, automotive, and hobby work. The type of parts that can be created is wide, ranging from things like sculptural pieces, circuit boards, and car parts.
Client Testimonials
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Jonathon Lanham2025-09-26Mike Allen and The Federal Group have been an absolute pleasure to work with. From the first day we reached out to them they responded punctually and professionally and helped us with every step of the process. We came to them with a budget conscious challenge and they delivered above and beyond a fitting and accurate solution. A quality finished part that has improved the overall quality of our product, and that's what really counts. Thank you to The Federal Group!Trustindex verifies that the original source of the review is Google.Sean Brockhouse2025-04-20Sandor Holzer has gone above and beyond helping us to get another part ramped up for production, creative getting samples ahead of schedule so we could meet tight timelines. Outstanding customer service!!Trustindex verifies that the original source of the review is Google.Melissa Quiroz2024-08-09Good company, knowledgeable staff, product was exactly what i asked for. Got me out of a jam!Trustindex verifies that the original source of the review is Google.Alex Armstrong2023-12-15Steve was great to work with and was always available when needed.Trustindex verifies that the original source of the review is Google.Jon Ramsey2023-10-07Mike at TFG was tenative to our supply needs and an immense help! Took on a project that was quite large and daunting, only to be resilient through the task challenges. In conclusion, everything was completed successfully and a huge success. Would recommend and I plan to use them for future projects. Thanks again Mike and TFG team.Trustindex verifies that the original source of the review is Google.Nic Robinson2023-10-05Steve Bogdanovich has been critical to our team meeting deadlines with a quality product. The communication and customer service is top notch. We know we can rely on Steve and The Federal Group team to get us a quality product and in a timely manner. We've sent all of our casted parts through them because we know we will get the best service, and they keep us informed through every step in the process.Trustindex verifies that the original source of the review is Google.Sean Connelly2023-06-21The Federal Group was great to work with. Steve was very professional and diligent in providing good advice/feedback as well as following up with me. Look forward to working with them in the future as well!Trustindex verifies that the original source of the review is Google.Sher Stahl2020-07-10The Federal Group is a top-notch supplier of ours. They take quality very seriously and strive to ensure we have exactly what we want and when we need it. Communication is excellent. Service is excellent. I have worked with this supplier directly for better than 7 years now, and still considered one of my best suppliers. We've recently expanded our product line with this company and are excited to partner on this line and on future projects. Words cannot express how grateful I am to have such a responsive company, and rep, Richard, to work with. I highly recommend this supplier.Trustindex verifies that the original source of the review is Google.Marshall2020-06-30Excellent customer service and products!
