Aluminum Sand Casting – Hackaday

As far as the hacker’s toolbox goes, the 3D printer is way up there in terms of utility. Sure, it takes time to learn the ins and outs of designing, slicing, and extruding, but after that, the world is pretty much your additive oyster. Follow those design dreams, or use it to replace the things that break. The icing on the cake? You can chase those dreams into other materials, because 3D prints can be used to cast metal.
[RetroTech Journal] wanted to fry up some rosette cookies, a Scandinavian delight from his youth that look a lot like fancy, personal funnel cakes. They’re made with special aluminium irons that shape the dough while it fries, as opposed to the jumbled chaos that is funnel cake.
Rosette irons come in a few traditional shapes, but once you get tired of those, it’s up to you to cast them in aluminium. And how would you go about doing that? By creating a firmly-packed sand mold using a mounted 3D print.
In the endlessly entertaining video after the break, [RetroTech Journal] takes you through the entire process from CAD to cookies. It has everything you could possibly want: LEGO stop-motion, claymation, a little bit of cooking, and a whole lot of knowledge. We can’t wait to see what comes next.
We’ve seen quite a few sand casting projects over the years, but this lathe is among the most useful.
Continue reading “Cast Metal From Prints To Solidify Childhood Memories”
If you’ve been on Reddit over the past year, you’ve likely encountered the “banana for scale” meme. [BFG121] felt that the size variation of bananas would not do – there needed to be a standard. He decided to make a metal banana out of re-purposed aluminum. He created his own furnace out of everyday objects including a hair dryer, metal bucket, cement, fire clay, and sand. [BFG121] used a typical banana as the reference for his sand casting mold. After melting the aluminum in his homemade furnace, he poured it into the empty mold, making sure there was an extra hole for the displaced air to escape. The end result is a perfect replica of a banana. [BFG121] made two aluminum bananas, and stamped each one with a serial number. One was given to Imgur headquarters while the other was auctioned on eBay. The winning bid (#39) was $67 USD, a very good ROI.
If you want to learn more about metal casting, check out myfordboy’s channel on YouTube.  You can also see an example of the “banana for scale” in this Hackaday article about a giant spirograph. Our only suggestion to [BFG121] is to send some to ASTM, NIST, and BIPM!
[via Reddit]
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