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The Process Made Perfect.

American Foam Cast is the expert in Lost Foam metal casting. Since our beginnings in 1997, we have dedicated our company exclusively to providing the highest quality and most innovative lost foam casting services for aluminum components. We offer our complete understanding of the process from concept to creation and work closely with our customers to ensure impeccable service from start to finish.

What is Lost Foam? 

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Lost Foam Casting, also known as the expanded polystyrene process, is a sophisticated, cavity-less type of metal casting. This process uses an EPS foam pattern rather than a die cast die or other tool, to shape molten metal into a high-precision component. The foam pattern is supported by sand packed in on all sides, leaving room for molten metal to be poured into the pattern. The heat causes the foam to evaporate, leaving behind a metal part in the desired shape.


We maintain a quality management system that is ISO 9001:2015 certified, and we take a proactive approach to ensuring quality throughout the casting process. From design to delivery, you can be sure that we are doing everything we can to provide you with the best customer service and the highest quality components.


Industries Served 

We can serve a wide range of commercial markets, providing components for applications such as lawn equipment, household appliances, and much more.


American Foam Cast is a trusted partner to a wide range of manufacturers in various aspects of transportation, including niche markets such as railroad and small electric vehicles.


Marine-related equipment typically has to undergo rigorous environmental conditions–and we’ll ensure that you receive components that are up to the task.


We can manufacture a wide range of rugged components for heavy truck engines and chassis requirements.

Heavy Truck

American Foam Cast is a trusted partner in casting aluminum components for those power generation applications that require the metal’s lightweight durability.

Power Generation

Request a Project Consultation 

Thank you for filling out our form and considering our services. We provide a custom and selective approach to each project we receive and will get back to you as soon as possible.