Graduate Research Papers


Open Access Graduate Research Paper


The expendable pattern casting (EPC) process was patented on April 15, 1958 by H. F. Shroyer. Shroyer's casting process required cutting a foam pattern out of a block pf expanded polystyrene and placing the foam pattern in bonded sand before metal pouring. This process became known as the full mold process. Later, in 1962, M.C. Flemmings is credited with using unbonded sand with the foam patterns (Monroe 1992). The use of unbonded sand is the process that we now refer to as expendable pattern casting. The process is a metal casting procedure that uses a polystyrene pattern instead of a traditional sand mold in order to produce castings. In the process, a foam pattern in the exact shape of the desired casting is coated with a ceramic coating to protect the surface finish and he structural integrity of the pattern. Next, the pattern is placed into a flask and unbonded sand is compacted around it. The molten metal is then poured into the flask and the metal displaces the foam pattern resulting in a casting that is the exact shape of the foam pattern.

Year of Submission

Summer 1993

Degree Name

Master of Arts


Department of Industrial Technology

First Advisor

Scott Helzer

Second Advisor

Ali Kashef


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Date Original

Summer 1993

Object Description

1 PDF file (23 leaves)



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