Investment Casting vs. Lost Foam Casting Comparison Table

Investment Casting vs. Lost Foam Casting Modulus Metal Turkey Türkiye 02

Detailed Investment Casting vs. Lost Foam Casting Comparison Table

CriteriaInvestment CastingLost Foam Casting
Process OverviewCreates a wax pattern, coats it in ceramic, melts out the wax, and pours molten metal into the cavity.Uses a foam pattern embedded in sand. When metal is poured, the foam vaporizes, leaving the casting.
Applicable StandardsASTM A356, ASTM E931, ISO 8062-3, and DIN EN 12890 for process quality and tolerances.ASTM A995, ISO 8502, ISO 8062-3, and VDG P690 for process quality, tolerances, and materials.
Tolerances±0.1 mm to ±0.5 mm depending on the part size and complexity. Typical tolerance grades: CT4 to CT6 (ISO 8062-3).±0.3 mm to ±1.0 mm based on part dimensions. Tolerance grades: CT8 to CT12 (ISO 8062-3).
Surface Finish1.6-3.2 µm Ra (fine surface finish with minimal post-processing).6.3-12.5 µm Ra (requires secondary operations for fine finish).
Material GradesFerrous: Stainless steel (e.g., 304, 316), carbon steel (e.g., AISI 1018, AISI 1045).
Non-Ferrous: Aluminum alloys (e.g., A356), brass, bronze.
Ferrous: Gray iron (EN-GJL-250), ductile iron (EN-GJS-400-15, EN-GJS-500-7).
Non-Ferrous: Aluminum alloys (e.g., AlSi12), magnesium alloys.
Size & Dimension LimitsSmall to medium-sized parts with dimensions typically ranging from a few millimeters to 1 meter. Maximum weight: up to 500 kg.Suitable for medium to large castings. Maximum part size can reach 2 meters or more. Maximum weight: up to 5000 kg.
Wall ThicknessCapable of producing parts with wall thickness as low as 0.5 mm.Minimum wall thickness: 2-3 mm due to process constraints.
Dimensional AccuracyHigh accuracy, typically within ±0.1% of part dimensions.Moderate accuracy, typically within ±0.3% of part dimensions.
Mechanical Properties– High tensile strength and good impact resistance, depending on alloy choice.
– Can produce parts with complex stress patterns due to uniform grain structure.
– Suitable for parts with lower tensile strength and ductility.
– Mechanical properties are more dependent on mold conditions and sand compaction.
Complexity & GeometryCapable of producing highly complex geometries with thin walls, undercuts, and intricate details.Good for moderate complexity; limited capability for intricate designs due to mold constraints.
Tooling CostsHigh initial tooling cost for wax and ceramic molds; more economical for high-volume production.Lower initial tooling cost for foam patterns and sand molds; more suitable for small to medium production volumes.
Production Volume SuitabilityIdeal for medium to high-volume production runs. Economical for large batches.Suitable for small to medium production runs. Preferred for prototype and medium series production.
Lead TimeLonger lead time due to mold preparation and multi-step process. Typically 4-8 weeks depending on part complexity.Shorter lead time due to simplified tooling and fewer steps. Typically 2-4 weeks.
Typical ApplicationsAerospace turbine blades, medical implants, automotive turbocharger wheels, and complex machinery components.Automotive engine blocks, pump housings, gear cases, and large, less complex structural parts.
Post-Processing RequirementsMinimal post-processing required. Parts are usually ready for use or only require minor machining.Requires secondary operations like grinding, machining, and heat treatment for surface finish and dimensional accuracy.
Environmental ConsiderationsCeramic molds and wax patterns have higher waste and energy consumption, but the process offers higher precision.Sand molds are recyclable, and the process generates less waste, making it more environmentally friendly.
Overall CostHigher overall cost due to complex molds and tooling. Cost-effective for high precision and complex parts.Lower overall cost due to simplified patterns and mold production. More economical for larger parts and low to medium complexity.
Investment Casting vs. Lost Foam Casting Comparison Table