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After mixing the volume should be double than that of the one before mixing.
This is done mainly to create a porous media so that the gases can escape easily. The unescaped gases are main causes for...

Getting porous casting may be due to various reasons such has, high pouring temperature, not fully degassing the metal, metal mold reaction.
1) Check the volume of your foam mold.
2) Dry the mold...

try HSS with 10% cobalt.

You may also convert a 2D pentograph machine to #D one and do any engravin in that. For engraving on harder material you can get high speed spindle

Thanks for your suggession.
I have seen DECKEL site and its interesting

I am interested in expanding my tire mould making unit in India.
I want to add machines for model making and sidewall engraving.
Can someone pl. suggest suitable machines and appropriate software...