Market Overview of Lost Foam Metal Casting and Forecast of Its Growth Until 2033 with Prospects of Development and Technology Digitalization

Abstract

The article presents a comprehensive analysis of the current state, macroeconomic trends, and technological prospects for the development of the Lost Foam Casting (LFC) process, dedicated to its 70th anniversary. Based on current monitoring data from global analytical agencies Grand View Research and Precedence Research, a stable expansion dynamics of the global LFC market is demonstrated, with a projected compound annual growth rate (CAGR) of 7.2% up to 2033. This growth is driven by the modernization of industrial production lines and the global transition to Industry 4.0 standards. Particular attention is paid to the scientific and technological experience of the Physico-Technological Institute of Metals and Alloys of the NAS of Ukraine in the field of digital transformation of pattern production. The concept of introducing additive manufacturing methods, specifically 3D printing of porous polymer patterns, is considered, which allows eliminating the capital-intensive and time-consuming stage of designing and manufacturing traditional metal tooling (molds). A significant advantage of integrating 3D-printed patterns is justified in terms of the absence of the need to recertify existing foundry shop structures, since the metallurgical essence of the casting process and the certification criteria for the final castings remain unchanged. The unexploited potential of the physicochemical and technological factors of LFC is revealed, including methods for regulating heat dissipation through vacuuming the dry sand mold, the possibility of differentiated heat treatment during melt crystallization, and obtaining ultralight frame-cellular structures based on topological optimization algorithms and artificial intelligence. The features of creating cast-reinforced structures for transport engineering with the integration of strengthening frames up to 15% by weight of the casting directly into the pattern body are described. The specific nature of gas-hydrodynamic processes during intense gasification of the polymer in the contact zone with the reinforcement is highlighted. To stabilize gas pressure, a methodology for controlled gas venting via a system of additional ventilation channels is proposed, ensuring both an increase in the geometric accuracy of castings and a high environmental effect due to the neutralization of hydrocarbon compounds. Keywords: lost foam casting; LFC process; 3D printing of patterns; foundry production digitalization; frame reinforcement of castings; topological optimization.