Tuesday, August 25, 2009

Lost Foam Metal Casting

http://www.buildyouridea.com/foundry/lost_foam_howto/lost_foam_howto.html
Someday, when I own a farm with several abandoned outbuildings and a rusty Land Rover, I am so doing this, oh yes.

18 comments:

Peter S said...

Very nice, but what exactly are they?

Andrew C said...

{Rolls eyes}
Well, if you need to ask, you don't need to know!

{BTW equally confounded, but unwilling to show my ignorance}

Paul M said...

I wanna know what happened to the foam and why no one is looking for it.

Peter S said...

It's probably down the back of the sofa.

Lloyd . said...

I like the bottom picture, I'm sure they're F16's.

Doctor Curry said...

Cool!

Randy Gilbert said...

I would like to make chess men this way some day.

Michael * said...

I admit to being slightly confused about the exact process this artisan is using to make perfect multiples. It appears that the sculptor is using a foam-core board (or something like it) to make his original plaster-covered model. Which then has to be perfectly replicated multiple times in order to make numerous copies.

So, while it is undoubtedly easier to carve and sculpt in a medium like "foam", each cast object is nonetheless unique, and the casting form will never be used a second time to generate another part or figure. Which seems like a lot of work to generate something like a single chess set with 16 pawns, 4 castles, 4 knights, 4 bishops, 2 queens and 2 kings, each of which requires individual carving which will be sacrificed in the pouring. So how does he get perfect multiples?

The author doesn't state, and it doesn't appear from his photographs, that he is using any form of of spray or injectable foam into a master mold made from an original solid part, carving or sculpture embedded in sand or plaster, or any other medium.

I think this is why most sculptors prefer to use the "lost wax" method, because you can use your original solid carving/sculpture repeatedly to make a master mold for the wax model, which will be destroyed in the casting process.

Matt F said...

Yeah, it does. Expensive in foam, too. Probably the best application for this is either one-offs, or coupled with some lightweight CNC machine churning out foam models.

Or really simply foam models.

Randy Gilbert said...

I dunno...I'm on the last few pieces of carving a chess set from marble, this seems like much less work.

Peter S said...

And the poster of Rita Hayworth...?

Andrew C said...

http://alloy-artifacts.com/peterson-carlborg.html
via
http://www.metafilter.com/84472/Exploring-Ingenuity-in-Iron

john smith said...

I made my chess set from cast concrete. The moulds, from flexible resin.

John Bush said...

1. e4

Matt Worldgineer said...

Duh. They're linear bearings.

(ok, I had to hunt around his site to figure that out)

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