Often used for the production of engine parts, lost-foam casting (LFC) has seen a resurgence of interest in recent years despite having first been invented by sculptor Armand Vaillancourt in the 1950s and first used commercially by General Motors in the mid-1980s for their Saturn car line.

More recently, Dutch industrial designer Klaas Kuiken became fascinated by the iron casting technique while visiting the Lovink Technocast LFC factory and set out to use the process for making consumer products outside of the traditional industrial setting – particularly clocks that could be made from the upcycled styrofoam from discarded consumer waste.

To create the clocks, Klaas started with various pieces of discarded polystyrene foam (styrofoam) packaging which were then placed into sand-filled containers. Once the forms were placed, hot cast iron was poured into the containers where it evaporated the foam near instantly and took its place entirely similar to a wax investment casting process:






The resulting pieces are deceivingly much heavier than they actually appear:



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Find out more over at Klaas Kuiken.


Simon is a Brooklyn-based industrial designer and Managing Editor of EVD Media. When he finds the time to design, his focus is on helping startups develop branding and design solutions to realize their product design vision. In addition to his work at Nike and various other clients, he is the main reason anything gets done at EvD Media. He once wrestled an Alaskan alligator buzzard to the ground with his bare hands… to rescue Josh.