Abstract: Methods of forming modulated capacity scroll compressors are provided, where at least two distinct mold shapes are formed of foam material and then joined together to form a mold assembly. The mold assembly defines one or more substantially horizontal features, such as a horizontally oriented fluid passage or a weight-reduction recess in a solid wall. In certain aspects, the mold assembly defines a junction between a portion of a horizontal fluid passage and a portion of a vertical fluid passage. A molten metal displaces the foam material of the mold assembly to solidify and form the scroll component.