| Lost-Foam Casting | Sand Casting | |
| Pattern Material | · Uses expanded polystyrene (foam), which evaporates during metal pouring. | · Uses a solid reusable pattern made of wood, plastic, or metal. |
| Mold Type | · Unbonded dry sand supports the foam pattern. | · Green sand (a mixture of sand, clay, and water) forms the mold. |
| Pattern Reusability | · Single-use pattern | · Reusable pattern |
| Surface Finish | · Produces a smoother surface with fine details. | · Surface is rougher, may require more finishing work. |
| Dimensional Accuracy | · High | · Moderate |
| Production Cost | · Higher initial cost but more economical for mass production. | · Lower setup cost but more labor-intensive for complex shapes. |
| Complex Shapes | · Excellent for complex and hollow geometries. | · Limited to simpler designs unless using cores. |
| Environmental Impact | · Less waste and binder usage, more eco-friendly. | · More waste generation due to binders and sand reuse issues. |
