Custom Rapid Prototype Casting Supplier
Rapid prototype casting is a process that uses a wax pattern to create a metal mold which is then filled with molten metal to create a new metal piece. The process does not require tooling and starts with a CAD design to create a wax pattern.
Request a Quote
Layers of material are bonded together using one of the various types of 3D printing methods like stereolithography, laser sintering, laminated object manufacturing, or fused deposition modeling. Once the part is made in wax, it is attached using wax to a sprue with other similar parts, and then coated in a ceramic slurry multiple times to build up a shell.
The ceramic slurry progressively gets more coarse to build shell strength. After the shell has been sufficiently built up, the wax is removed through heating in a furnace or autoclave, leaving just the shell. The shell can then be prepped through a higher heat before the molten metal is poured into it. After cooling and removal of the shell, a new metal part is left.
The coated foam mold is packed securely into a flask and filled with heavily compacted, unbonded sand. A molten hot metal, usually an aluminum alloy, steel, or cast iron, is carefully poured into the flask and over the foam mold. The polystyrene foam mold evaporates as it comes into contact with the metal and is replaced by the metal leaving the same shape. When the metal has cooled, it is pulled out of the ceramic coating and the excess sand or debris is cleared off, leaving a finished metal piece.
Advantages/Disadvantages
The main advantage of lost foam casting is that complex castings can be created in a highly cost-effective manner. There is minimal machining required and the tooling used will not wear down. Large runs of metal pieces can be created with excellent surface finish properties and the cleaning cost is lower. Unbonded sand is simpler to maintain and foam molds can easily be manipulated. This allows for ease of creation in making unique pieces, so prototyping finds great use of lost foam casting.
Disadvantages include higher costs for molds if there is a low volume created as well as a higher starting cost if a die is used to create the molds. Molds can also be easily damaged due to the low strength of the material.
Applications
Lost foam casting historically has been used in automotive manufacturing to make a variety of pieces including cylinder heads and that continues with widespread use in the automotive industry. The low cost also makes lost foam casting popular among hobby foundries and artists alike.
Client Testimonials
Trustindex verifies that the original source of the review is Google.
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!
