L.S.F.C / Lost Soft Foam Casting
Taehun Ko was inspired by “Evaporative-pattern casting” however, it requires and wastes materials to make objects. Thus he explored the way of solving problem as well as new aesthetics. I experimented with various types of soft foam sheeting and finally settled on using Plastazote LD18 and a small hand torch to heat weld the pattern ready for sacrificial casting. The softness of the foam together with the tailoring technique and heat-welded seams present a unique natural plump appearance. Each foam master is ready to be cast at the local foundry in only 15 minutes.
category / furniture, low stool
material / cast aluminium
W 365 x D 330 x H 440
Show RCA 2014
After long experiments in order to explore proper material for “Lost Soft Foam Casting” process, Taehun discovered specific LDPE (Low Density Polyethylene) foam - LD18. Common “Lost Foam Casting” uses an solid block of EPS (Expanded Polystyrene) foam. However unlike it, he used sheeting material in order to create unique aesthetic of product. By using simple tools such as a cutter and hand blow torch, he could tailor this material in order to convert from 2D to 3D. Foundry man taught me to pack the sand same as sand casting process and use silica sand with carbon dioxide for keep its shape in the mould. Molten aluminium is cast, and it replaced soft foam inside of sand mould. So that it presents the unique result looks like natural shape of foam.
Thanks to the sheet material, he could reduce the material wastes compare to the general lost foam casting process. Also, it cut down additional process, which is making solid mould for the patterning. One sheet of LD18 foam is 2m X 1m thus one stool can be made out of half sheet of material in the market. This process could be applied to create any objects depending on the pattern works.