Pattern for the lost foam casting process including a pouring-basin-foming
portion, a sprue-forming portion, a runner-forming portion, a gate-forming portion,
and a riser-forming portion. The sprue-forming portion forms an inverted conical
sprue having a blade-lightener therein for quickly filling, and substantially simultaneously
firing, the gates. A glue joint may be used between the pouring- basin-forming
portion and the sprue-forming portion to increase the residence time of the melt
in the pouring basin. The runners formed by the pattern each have an inline riser
through which melt flows during pouring and in which melt is stored to feed the
casting with melt during shrinkage of the casting A sand dam surrounds the mouth
of each gate and traps particulates from a liquid styrene layer that precedes the
melt front in the riser.