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<p>The lost foam casting process has used expanded polystyrene (EPS) as the pattern material since the inception of the process. The expanded polystyrene is derived from petroleum distillation which carries a heavy carbon footprint and health concerns from the decomposition products during casting. A novel molding bead technology has emerged that derives an expandable polylactic acid (EPLA) foam molding bead from sustainable domestic biological sources. Bio-based foam patterns were evaluated for their potential to replace EPS as a lost foam pattern material using laboratory testing and casting trials. The laboratory results showed the EPLA materials did not produce hazardous air pollutants nor carcinogens. The casting trials successfully produced lost foam castings in both aluminum and gray cast iron without any modifications to the lost foam casting process.</p>

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Bio-Based Foam Patterns for Lost Foam Casting

  • 期刊论文

  • 发表日期：

    2025年6月14日

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  • Jacob Belke,
  • Adam Kopper,
  • Tedd Sheets,
  • Dan Mueller,
  • Sam Bhargava,
  • Chris Mercy,
  • Jonathan Godfrey

摘要

The lost foam casting process has used expanded polystyrene (EPS) as the pattern material since the inception of the process. The expanded polystyrene is derived from petroleum distillation which carries a heavy carbon footprint and health concerns from the decomposition products during casting. A novel molding bead technology has emerged that derives an expandable polylactic acid (EPLA) foam molding bead from sustainable domestic biological sources. Bio-based foam patterns were evaluated for their potential to replace EPS as a lost foam pattern material using laboratory testing and casting trials. The laboratory results showed the EPLA materials did not produce hazardous air pollutants nor carcinogens. The casting trials successfully produced lost foam castings in both aluminum and gray cast iron without any modifications to the lost foam casting process.