The latter process uses beads of polystyrene that are heated inside an aluminum die to expand and fill the die. A completed polystyrene foam mold is then covered with a ceramic refractory coating to create a barrier between the foam and the sand in which the foam mold sits. The small amount of waste gas created can escape into the sand.
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There are many advantages to rapid prototype casting. There is a reduced cost and lead time to create a part. There is little to no machining needed and there is a high level of design freedom. Incredibly complex shapes can be created with various characteristics that are difficult to achieve with other methods. An example is parts with thin walls.
The finished metal parts have a nice surface finish. A large disadvantage can be the time it takes to create a CAD design as well as the level of expertise it requires. Part sizes are also limited to the size of the printing area in the machine creating them. The metals that finished parts can be created in is limited by metals with a lower melting point.
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I remember on AA, metalbynevin (a guy with a good number of successful lost foam pours under his belt) had a theory that polystyrene vapour residue builds up in the sand, and that once it reaches a certain concentration, it can cause or aggravate sand float defects which sometimes occur if you pour the soup can Kush tool too full when the pattern isn't buried under a heavy enough load of sand to counteract the hydraulic pressure. If true, I can see how it would be easy to misdiagnose as such. I don't know if there is any validity to that, it was only briefly discussed, but if so, maybe it is possible the sand may need to be replaced (or burned clean?) every so often. If that is a real thing, perhaps it is only of concern if you've been pouring cool enough to see a lot of those tell-tale sand lumps? Jeff
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