Forge & Casting

Casting is a manufacturing method and an art form which stretches back millennia. Starting with aluminum due to its low melting point, I constructed a backyard forge using a steel bucket, insulation, a graphene crucible, pvc piping and a hair dryer. Insulations was made out of play sand, plaster of paris, water and thick steel wool. Aluminum was sourced through recycled cans, and once molten, poured into steel baking pans to form “muffin” ingots. Blending the advanced technology of 3D Printing with casting was always interesting to me. When given the chance I took opportunity of designing a casting tree to be printed out of Formlabs Castable Resin. An investment mold was then poured and burnt out for casting purpose.

The first pour

Concrete Casting

Continuing the combined use of 3D printing with casting, an on and off project of mine has been the printing of molds for concrete statues and parts. All molds have been printed on FDM machines out of PLA. Heat Set inserts were used on molds which required assembly, all molds are treated with standard mold release spray before pouring. Concrete used has been Quikrete High Strength or Quikrete Fast Setting Powder combined with water at the appropriate ratios. Currently all pours are then mechanically vibrated with a DREMEL Engraving tool to remove all air bubbles and ensure good surface quality. 24-48+ hours is given for the concrete to dry before mold removal.

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Titanium LPBF

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Incense Frog