Engine Blocks Lost Foam Production 

My Saturn engine was actually painted styofoam...

Only the 2.2L block goes through this process, the 2.4 and 2.0 are old-fashion Forged Aluminum.

The sand has oil in it and its very sturdy once pressed together like building a sandcastle

1.the sand is not loose but well compacted surrounding the cluster 2. the ingredients are patent covered

The exact composition is trade secret (read: NOT pattened as Aldo claims, as that would require disclosure of the blend, similar to why fragrances aren't pattened). What I can share is the primary 'special' components, excluding its water base are graphene and iron. A combination of the refractory coating and the density of the molten metal is sufficient to maintain the mould shape. the sand is compacted via vibration of the flask prior to casting.

You can buy a similar product called polycap 600 it's pricy though

@2:22 you see the foam parts dipped into a slurry. this coats the foam in a refractory that acts as a barrier between the loose sand and the foam mold.

Still awesome to see how a block is mass produced.

lol