The process is the energy lost foam casting process the most effective available. “Foundry Management & Technology” magazine analyzed the lost foam process and reporting energy savings of 27%, 46% improvement in labor productivity and 7 percent less material weight compared to other molding processes. Produces the Lost Foam Casting Process high value parts to combine cast components in a single projection, improve energy efficiency through better metal production to achieve, to reduce material consumption by removing cores, while improving dimensional accuracy solutions.
All of these features reduce process energy consumption during manufacturing. For example, achieved energy savings of 7.7×1012 BTU / year change Cast Iron, ductile iron and aluminum castings produced by the sand and shell molding processes to Lost Foam green. Lost foam casting production has grown in value from about $ 5 million per year in 1988 to $ 800 million in 2002. This is the result of ongoing investment by the industry with financial assistance from the DOE Office of Industrial Technology. During the period of time is quite technical issues have been resolved and the transfer of technology to the production floor, resulting in reduced waste from 25% to less than 3%.
This program has reduced waste solutions and maturation of the technology by expanding the market Lost Foam. With the economic downturn in 2006 and a major supplier of automotive decision to change to another casting process has significantly reduced the LFCP. The process continues to grow slowly through suppliers Lost Foam Casting existing new product introduction using the attractive features of the process.