Full Mould Casting
What is the Full Mould Process
Full-mould casting is an evaporative-pattern casting process. It uses an expanded polystyrene foam pattern, which is then surrounded by sand, much like sand casting. The metal is poured directly into the mould, vaporizing the foam on contact — ideal for complex, low-volume and project-based parts.
Advantages
- Supports complex shapes.
- Highly accurate.
- Highly efficient (produces little or no waste).
- Costs less than traditional wax-based casting processes.
- Doesn't require draft or flash.
- Supports a variety of sizes, ranging up to several tons.
- Can be used with molten aluminium, steel, iron, copper, alloys and many other metals.
Disadvantages
- Pattern is consumed during the process.
- A new pattern is required for every new casting.
- While inexpensive at high volumes, full-mould casting typically costs more than other processes for low-volume applications.