Rapid casting gives the opportunity to develop a new casting in days, not in weeks or months. Evaporative Pattern Casting (EPC) process gives flexibility to produce complex geometries by integrating several parts in single casting. The lead-time and cost involved in designing and fabricating the metal tooling for Expanded Polystyrene (EPS) pattern making can be overcome by using the Segmented Object Manufacturing (SOM) machine. This hybrid system of pattern making is explored with all sub-systems and a complicated EPS pattern is produced by this Rapid Prototyping system. Conventional EPC process is more complicated due to coating development, vacuum assisted metal pouring and vibration system for filling the cavities by unbounded sand. In the present work, different mold-making processes are explored to avoid complications of conventional process. The Green sand, No-bake sand, and Plaster of Paris molds are prepared using Rapid Prototyped EPS pattern to produce the castings. The castings are characterized by comparing the surface roughness, dimensional accuracy, hardness, and surface morphology.