How to "MAKE:"...
...a simple casting project
Draft toolpath in any vector based editor that supports "DXF" export.
Convert DXF to GCode, the language of the CNC Mill...
Machine the Gcode into EPS construction foam.
Trim patterns from machined flat to size, shape and desired thickness.
Clean-up patterns, ie; sanding, and adding any fixtures (in this case eye screws from the local hardware store.
The patterns are packed into sand below for casting...
The patterns are packed as a "Cope & Drag" casting. The patterns are oriented face-up and sand is rammed in to form the "cope" or bottom of the mold.
The Cope is rolled to expose the backs of the patterns. Sprues or feeders are Hot-Glued to the backs of the patterns.
The drag or top of the mold is added and the backs of the patterns are rammed with sand to complete the mold.
A trowel is used to form a pouring spout around each sprue to guide the liquid alloy into the mold.
It was -25C on the day I poured the castings, so I didn't take the camera outside to take pictures (but there are lots of images elsewhere on the site showing castings being poured.)
The poured castings are shown above, they still have their feeders attached, these are remelted into the next castings.
The castings are cleaned or fettled, this involves wire-brushing, grinding and sanding.
These castings are dipped into a latex enamel paint and hung to dry.
The castings are surface finished with a 220 Grit sandpaper in a belt sander.
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