is there any way to make a 3D mold for aluminum casting?

In some of the aluminum foundry instructables I've read, the molds only have 1 side. I was wondering if anyone knows how to make a 3D mold?

Prfesser8 years ago
I have made a number of molds that didn't have a "flat side". There are several ways to do this, but the main thing to remember is that the pattern must slope from the parting line (the line where the two halves of the mold meet) such that the pattern can be removed after molding.

For an example, take a look at "Homemade Aluminum Pulleys" at http://www.backyardmetalcasting.com/index.html. It shows both how to cast such a part and how to use "cores" to produce holes in a casting.

Another method of making intricate castings is the lost-foam process. A good example is shown at http://www.buildyouridea.com/foundry/lost_foam_howto/lost_foam_howto.html

Hope this helps!
Another way to make a 3-D mold, but rather more challenging, is the creation of a soapstone mold. In essence, one must craft two halves of the mold from two plates of soapstone, which is soft enough to carve with a dremel, but strong enough to withstand molten metal. The pieces are then bound together with wet rawhide, which is allowed to dry, causing the pieces to be pressed together extremely tightly. Casting then occurs as normal, but this method has the added benefit of a reusable mold over lost wax or lost foam.
lennyb8 years ago
you might also try the lost wax casting method. but you need to be sure to burn out the wax completely before pouring molten metal or you will get unwanted bubbles and voids in your item.
lemonie8 years ago
You want to cast complex things with holes in? This is getting a bit advanced, see this link for more: