Turning 3D printed plastic parts into metal objects is not a new concept. But we don’t see a lot of it and enjoyed watching the documentary version of [3DTOPO’s] lost PLA metal casting process so much we figured you’d want to see it too.
The thirty-five minute video walks through every part of the process which we originally learned about in September of last year. The process was developed as a way to fabricate parts that will be used in high-stress applications. For instance, the part seen above is a mounting bracket for the ball screws that moves the Z axis on a huge CNC build he’s been working on. A plastic part will break under the strain so he needed to make it out of aluminum alloy.
To start, the piece is modeled and printed in plastic to check the fit. Once it’s just right he scales it to 103% and prints it again to account for the shrinking of the metal as it cools. The next step is pictured above, adding paths using rigid foam insulation that allow for the metal pour and for air to escape. This is packed into a plaster and sand mold which dries before being cooked in a furnace to vaporize the foam and PLA. This leaves a perfect mold for the metal pour.
After the break you can see a 5-minute overview version of the project.
Continue reading “Update: lost PLA metal casting — The Movie”
If you want to do casting at home, you’ll need a way to melt metal. [Jake]’s DIY foundry furnace gets hot enough to melt aluminium, and is built out a mix of scrap parts.
The chamber of the furnace is built out of a water heater tank which has been lined with a special cement that refracts heat. The furnace is heated by a Babington burner. This type of burner works by atomizing the fuel and injecting it into the furnace. They are good for burning waste oil to achieve high heats.
A scrap Volkswagen oil pump and a cordless drill are used to feed oil into the burner. Once it’s fired up, the furnace takes about 10 minutes to melt the 11 pounds of metal that it can hold. [Jake] melted about 40 pounds of aluminium alloy from scrap alloy wheels in 2 hours, which should be more than enough for a home casting project.
After the break, check out the overview of the device and a demo of melting aluminium.
Continue reading “Melting Metal with a DIY Foundry Furnace”
Need fifty copies of that 3D printed whirligig you’re so proud of? It might be faster to just cast copies by using the 3D printed model to make a mold. [Micah] found himself in this situation and managed to cast one copy every 10-12 minutes using the mold seen above.
With the object in hand, you need to find a container which will fit the mold without too much waste. The bottom half of the mold is then filled with modeling clay, a few uniquely shaped objects to act as keys, and the model itself. After getting a good coating of release agent the rest of the mold is filled with a silicone rubber product which is sold for mold making. This creates one half of the mold. After it cures the clay and key objects are removed, everything is sprayed with the release agent, and the other half of the mold is poured.
Now your 3D object can be copied by pouring two-part resins in the to shiny new mold.
[Jeshua] needed a laser head attachment for a 5×10 foot CNC machine he’s working on. Because he has a 3D printer, [Jeshua] could easily print a laser mount and attach it to his CNC gantry, but that wouldn’t look very professional. Instead of decorating his gigantic machine with brightly colored plastic, he decided for a more industrial look by casting a laser head in aluminum using a 3D printed master.
[Jeshua] designed two parts for his laser cutter in OpenSCAD and printed them out on his 3D printer. A few bits of foam insulation were glued on to act as sprues, and an investment mold was made out of 1 part Plaster of Paris and 1 part playground sand.
After the mold had cured, [Jeshua] put is mold in a coffee can furnace to burn out the wax and foam. These hollow molds were placed in sand and the crucible loaded up with aluminum scrap.
The finished laser head fit his CNC machine perfectly – no small feat, considering [Jeshua] needed to take in to account how much the aluminum would contract after cooling. Not bad for one day’s work.
This completely DIY casting furnace turned out just great thanks to all the work [Biolit11] put into it along the way. He wanted to replace his older furnace with one that was more efficient, and to that end he built a heat exchanger into the design. This way the exhaust will preheat the intake air.
The furnace itself started with the shell of an old electric water heater. Excluding the design process, the majority of the build involved mold making. For circular parts he’s using quick tube, the paperboard forms used for pouring concrete footings. For more intricate parts he shaped polystyrene. They are layered in place and high-temperature cement is poured to form the permanent parts. After it hardens the polystyrene can be removed in chunks.
The heat exchanger is the part to the left. It includes several wide, flat pipes made of cement for removing the exhaust. Around those pipes a snaking metal chase carries the intake air which picks up the heat as it passes over the exhaust pipes.
For his first run with the new furnace he melted down a bunch of scrap aluminum and poured ingots.
Typecasting is the name of the game here. By starting out with an empty array formed by a pair of square brackets, [Patricio] can generate the number zero by casting the array with the plus sign. From there he can use an exclamation point (a boolean cast) and addition to generate any number. The image above is an example of the digits 0-9. This would get very tedious for larger numbers but there’s another shortcut. Cast the digits to strings, concatenate them, then cast back to a number and you’re in business.
Here’s one good thing about the bitter cold Midwestern winter, it helps keep you from overheating when working around a hot furnace. Back in February this iron pour happened in the parking lot of the Madison, Wisconsin based Sector67 Hackerspace. Look, they’re making iron hearts!
Now this isn’t just a bunch of members who got together and decided to do some casting. As you can tell in the video after the break the team knows what they’re doing. The event was a collaboration with FeLion Studios, a custom cast-iron art boutique. But the Hackerspace participants did get to take part in the process of building the cast, watching the pour, and cleaning up the rough results.
One of the people from FeLion Studios just appeared on the Martha Stuart Show, along with a 550 pound cast-iron frying pan United States map. [Chris] from Sector67 tells us the New York frying pan that [Martha] is hold was a product of the parking lot pour.
Continue reading “Iron casting in the parking lot”