FOUNDRY PATTERN MAKING WITH EPS RIGID FOAM

FOUNDRY PATTERN MAKING WITH EPS RIGID FOAM
FOUNDRY PATTERN MAKING WITH EPS RIGID FOAM

Foundry Patternmaking with EPS Rigid Foam – Precision, Innovation and Efficiency in Modern Casting Patterns

CNC-Machined Rigid-Foam Patterns Made from Expanded Polystyrene for Cast Parts of the Highest Quality

The foundry patternmaking with EPS rigid foam (expanded polystyrene, polystyrene foam, Styrofoam) by Evomatec stands for modern pattern technology in precision casting. Our high-resolution CNC-machined rigid-foam patterns made from EPS rigid foam, polystyrene rigid foam or polystyrene foam are specifically developed for demanding foundries and metal casting plants that rely on high dimensional accuracy, surface quality and reliable process stability

The combination of digital CAD/CAM design, 5-axis milling technology and application-optimized EPS rigid foam enables foundry patterns for prototypes, one-off parts and serial casting to be manufactured efficiently and precisely. Whether a foam pattern as a lost pattern in the lost-foam process or as a master for downstream processes – Evomatec delivers the complete solution from design analysis to the ready-to-use pattern

Precision Patternmaking for Cast Parts with EPS Rigid Foam, Polystyrene Foam and Styrofoam

Our EPS rigid-foam foundry patterns feature high shape stability, low weight and very good machinability. Expanded polystyrene is especially popular in patternmaking because complex geometries can be produced economically and the patterns can be used in a process-appropriate manner in different casting methods

In the lost-foam process, the foam pattern is embedded into the molding material and is replaced by the molten metal during pouring. This creates cast parts with very high design freedom, especially for complex contours, integrated radii and near-net-shape geometries. Through CNC milling of polystyrene rigid foam, highly detailed contours are produced – from simple patterns to complex pattern segmentation for large components

Advantages of Evomatec Foundry Patternmaking Technology

1. CNC Precision with Digital Pattern Design

Our patterns are fully designed digitally. 3D data (STEP, IGES, STL) is transferred directly into production to realize precise rigid-foam milling and dimensionally accurate EPS rigid-foam pattern segments. This enables short lead times, reproducible quality and fast changes during the development process

2. Application-Optimized Selection of EPS Rigid Foam and Polystyrene Rigid Foam

We process EPS rigid foam expanded polystyrene, polystyrene foam, polystyrene rigid foam and, depending on requirements, additional foam materials. The selection is made per project based on component size, level of detail, surface requirements and the desired casting process, so that the foam pattern functions reliably in your production

3. Versatile Application Areas

Our patterns are used in the following areas:

  • foundry patternmaking for aluminum casting, iron casting and steel casting

  • lost-foam process and foam pattern casting

  • patternmaking for prototypes, single parts and series production

  • CNC-machined EPS rigid-foam patterns for sand molds and process-related ceramic applications

  • custom designs, pattern repairs and data modifications

4. Cost-Effective and Efficient

The foundry patternmaking with EPS rigid foam enables short manufacturing times and a highly economical implementation, especially for prototypes, small series and development projects. Patterns can be adapted, segmented and duplicated quickly without long tooling lead times

5. Process-Reliable up to Handover to the Foundry

On request, we deliver the foam pattern ready for assembly, including segmentation, bonding-joint planning and foundry-appropriate design. This gives you a pattern that is easy to handle in your production and provides the basis for reproducible casting results

Technical Features

  • Materials:EPS rigid foam, polystyrene foam, Styrofoam, EPS rigid foam expanded polystyrene, polystyrene rigid foam

  • Manufacturing processes: CNC milling (3- to 5-axis), sanding, patternmaking based on CAD/CAM

  • Tolerances: up to ±0.2 mm depending on pattern size, component geometry and process requirements

  • Pattern size: up to 7000 × 2000 × 1000 mm

  • Application areas: aluminum casting, iron casting, steel casting, prototype casting

  • Processes: lost-foam process, foam pattern casting, full-mold process

Evomatec – Your Partner for CNC-Machined EPS Rigid-Foam Patterns

With many years of experience in precision foundry patternmaking, Evomatec develops project-specific solutions for foundries, mold makers and industrial companies worldwide.
Our EPS rigid-foam and polystyrene rigid-foam patterns are designed for dimensional accuracy, repeatability and process-reliable handling – tailored to your components, materials and manufacturing workflows

Each pattern is produced with modern CNC technology, clean surface preparation and technical know-how – Made for Precision

Contact

Are you planning a new foundry project or do you need a custom-made EPS rigid-foamfoam pattern?
Contact us for a personal consultation or an individual quotation

Contact our sales team: info@evomatec.de


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