Foam Patterns Replacing Wax in Production

FOPAT Production Inc. (FPI), Miamisburg, OH has moved into a new 14,000 sq ft facility to commercialize of a foam pattern-making technology. With new injection machines in place, FPI is ready to produce foam patterns for investment casting foundries and other component manufacturers. After $1.5M and 2+ years R&D, we are now in production and taking orders!

This new foam pattern FOPAT, was the result of work funded in part by a two-year DOE Inventions and Innovation program grant as well as a six-month Phase I and a two-year Phase II DOD Small Business Innovative Research (SBIR) grant from the Air Force Materials Command at WPAFB. FOPAT is a proprietary mix of components which react and expand
to form a foam-like product. The new product, in combination with a modified RIM process and alternate tooling methods, has been used to create investment casting patterns with smooth surface finish and excellent dimensional predictability.

Additionally, the foam patterns are temperature-stable, energy-efficient and cost-effective, and can be processed using standard investment casting techniques. The autoclave portion of the traditional investment casting process may be eliminated entirely. Researchers estimate that U.S. investment casters could save $5 million per year in energy
savings alone as a direct result of replacing wax patternmaking (and wax melt cycles) with the proposed FOPAT method. They also calculate an additional savings of $140 million in productivity, material savings and scrap reduction. To learn more, call Nick Cannell at 937-272-2709 or visit us at FOPAT.com.

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