top of page
Sichtkontrolle.jpeg

Lost Foam
Casting

To design, set up, and operate a state-of-the-art Lost Foam Casting foundry producing high- precision Grey and Ductile Iron castings, aimed at supplying world-leading OEMs across automotive, industrial, and heavy machinery sectors, while achieving industry-leading quality, cost efficiency, and sustainable profitability.

Key Areas of Work

1. Strategic Feasibility, Business Planning, and Foundry Layout

  • Conduct technical, financial, and market feasibility studies specifically for Lost Foam technology.

  • Develop a full business plan including investment modeling, cost structures, ROI projections, and growth roadmaps.

  • Design an optimized foundry layout — from foam pattern production, coating, drying, molding, pouring, to finishing and inspection areas.

  • Integrate environmental controls for VOC (Volatile Organic Compounds) and emissions management.

2. Technology Selection and Infrastructure Development

  • Selection of world-class equipment and technologies:

    • Automatic foam molding lines

    • Robotic coating stations

    • Advanced drying ovens

    • Precision pouring systems (gravity/vacuum-assisted if needed)

    • Material handling automation

    • Set up fettling shop

    • Set up machine shop and paint shop

  • Setup of foundry utilities: sand systems, reclaimers, dust collection, cooling towers, and energy management systems.​

3. Process Engineering for Lost Foam Casting Excellence

  • Define and establish robust LFC processes:

  • EPS (Expanded Polystyrene) pattern design optimization for casting accuracy.

  • Coating technology selection for permeability control.

  • Sand compaction and fluidization control systems for defect-free castings.

  • Metallurgical recipes tailored for Grey and Ductile Iron in LFC environment ensuring optimal mechanical properties and dimensional accuracy.

4. Quality Systems and Global OEM Compliance

  • Develop and implement ISO 9001, ISO 14001, ISO 45001 and IATF 16949 compliant quality management systems.

  • Set up inline defect detection systems (X-ray, UT, MPI, scanning for complex parts).

  • Establish laboratory facilities for metallography, tensile testing, microstructure analysis, and chemical composition validation.

​

​

5. Operational Excellence and Lean Foundry Model

  • Deploy Lean Manufacturing principles (5S, SMED, Visual Management, Root Cause Problem Solving).

  • Implement advanced tracking systems for scrap rates, rework analysis, and cycle time optimization.

  • Set up TPM (Total Productive Maintenance) programs for high equipment availability and uptime.

6. Digital Foundry and Industry 4.0 Adoption

  • Smart sensors across foam molding, drying, pouring, and cooling stages.

  • Real-time monitoring of casting parameters through IIoT platforms.

  • Use of Digital Twins for process simulation, optimization, and predictive maintenance.

  • Develop and implement SAP for real time data/MIS systems

7. Workforce Building and Skill Development

  • Recruitment strategy for key technical roles: foam engineers, metallurgists, process engineers, quality inspectors, maintenance experts.

  • Training modules for Lost Foam Casting technology, advanced problem-solving (8D, A3), and operational excellence practices.

  • Leadership development programs for building a world-class manufacturing culture.

8. Business Development and Strategic Customer Acquisition

  • Strategy to obtain approvals from global OEMs (APQP, PPAP submissions).

  • Customer engagement programs to position the foundry as a strategic long-term partner.

  • Roadmap for diversifying customer base across automotive, tractor, pump, motor,heavy equipment, and renewable energy sectors.

9. Sustainability and ESG Compliance

  • Best practices for energy optimization, sand reclamation, and emissions control.

  • Initiatives for carbon footprint reduction and renewable energy integration.

bottom of page