foamcast as the name suggests uses a molded Polystyrene Foam Pattern which is further processed to form an inert, fired ceramic mold. The molded Polystyrene Foam Pattern is dimensionally accurate and has an even smooth surface finish.
With the use of sophisticated aluminum tools/molds/dies Polystyrene Foam Patterns with no parting lines, no cores, and zero draft angles can be molded. In case of extremely complex castings the Polystyrene Foam Pattern can be easily glued together to create the intricate challenging surfaces.
In short the foamcast - lost foam casting process achieves the quality and precision of the traditional investment casting process that was limited to small castings in larger castings too.