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Why Model Foam Patterns?

Foam pattern quality is important throughout the shape molding industry; however, foam pattern quality is of the utmost importance to the lost foam casting industry: an ongoing industrial research consortium and SeeFoam customers found that most of the defects in lost foam castings can be traced back to the foam patterns themselves. Sometimes the non-optimal quality of the patterns is visible and severe, but often it can be more subtle and appears as inconsistent pattern density and fusion. This can cause the metal front to “finger”, resulting in porosity and other casting defects. A tool was desired to model the creation of the foam patterns themselves, which led to Seefoam.