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Build a foundry and sand-cast aluminum.

Step 14Pouring the mold

Pouring the mold
The most self-explanatory step. Pick up your crucible with your tongs and pour the molten aluminum into your mold.

The aluminum has a smooth look to it's surface while it's still molten, but if you watch closely, you can see it start to crystallize.

Try not to pour from too high or the aluminum will crush the detail out of the mold.

Again, I apologize for the lack of videos, I'll try to upload some soon.

Here's a pic of the finished product. (I didn't use enough aluminum) :(
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11 comments
Sep 29, 2010. 7:32 AMFirestorm_101 says:
How do you make 3d designs like ring, bracelets, bangles, etc? Could you put a material within the sand with a gap uptop, that would incinerate immediately while pouring in the molten liquid?
Oct 6, 2010. 9:17 PMbadideasrus says:
..... it wont let me reply to myself..... oh well. the show was called 'animal face-off' i can't find a full video, so i cant find the casting stuff, but i liked it so much i wrote it down as a kid once..... so i'm pretty sure i've got it right. the only thing (besides it being a special sand or not) was weather they used a sprue hole..... which kind of ties in to the sand being special or not, cuz iron sand would melt, making a hole...

but hes, you could use a burnable material.... look up lost wax casting. same thing, basically, just without the sand.

==========================================================note:
sand casting wouldn't work so well with jewelry, though..... unless you have extremely fine sand, your detail level will be degraded, cuz your detail is restricted to the size of the grains of sand. if it's course, it will leave pits and bumps in the surface of your jewelry.
Oct 6, 2010. 8:58 PMbadideasrus says:
there was a show were they would see which of two animals would win if they ever got into a fight. i loved the show, not only because of the awesome idea, but because they always made a black iron replica of said animals skull (complete with teeth) or claws or what not .... ON THE SHOW. they even exsplained what they were doing.

they would pretty much do sand casting, however they would use foam, like styrefoam, that they carved into shape, and just pour the molten metal onto the sand. i don't think they even made sprue. of course, i think they used iron sand..... may be important....

the downside to this is that the metal was kind of pitted.
Nov 14, 2010. 6:08 AMneorazz says:
i remember that show they would overcast the teeth and then polish them down to size i though them to be unrealistic in comparison to the same size tooth in enamel/bone (much higher psi before breaking) but the metal work idea is sound if your making your own foam molds enlarge them a bit then you can machine off the excess for a good finish where you need it
Dec 5, 2010. 10:09 AMbadideasrus says:
hmm.... good point. i didn't remember that. i agree about the breaking thing though. very hard to gain real evidence without useing real props.... still, you can't say you wouldn't love haveing a solid steel tiger skull on your dresser.
May 7, 2009. 6:49 AMjuntius says:
its better to use other aluminum than cans.. get some old junk from the junk yard to melt down... old aluminum frame chairs. windows. etc.. cans have a lot of slag...
May 7, 2009. 5:14 PMWyle_E says:
The best scrap for casting is old castings, such as mall engine blocks, pump castings and frames from dead computer hard drives. Thicker sections yield more metal and less dross. Just make sure that a casting is aluminum. Some are zinc alloys and a few will be magnesium. Zinc alloys, sometimes called "pot metal", melt lower than aluminum and are good for small parts, but beware of the fumes. Magnesium can be really bad news. Get it too hot and it will ignite. Once that happens, you can't do much but run away and wait for it to burn out. Magnesium will burn in an atmosphere of pure steam or even carbon dioxide. There is a simple test: scrape or sand a clean spot on the metal and put a drop of vinegar on it. Magnesium will react to form bubbles; aluminum or zinc will not.
Jul 6, 2009. 8:33 AMrobotmastern says:
zink vapor is also toxic
May 8, 2009. 6:22 AMjuntius says:
great post... i've been collecting old hard drive cases for my next melt.. i'll do a test on em now!
Jun 17, 2009. 2:46 PMBenson1 says:
You also wouldn't have to worry about the mold losing its shape if you mixed your sand with lots of oil. If it's fine sand and oil you could even make a finger print in it and it would still be solid.
Jun 19, 2009. 5:52 AMarcane2rox says:
It's true! that what's used even with an Iron foundry. I have used one in metal shop back in High School!
Apr 20, 2009. 10:18 PMGraffix10g says:
how many cans is that?
Apr 22, 2009. 3:34 PMERCCRE123 says:
he said it's not made from aluminum
Apr 23, 2009. 9:31 AMspiderx says:
Wrong. He said its not "enough" aluminum.
Apr 21, 2009. 1:49 PMFlashflint says:
I too would like to know how many cans were used to produce the chuck seen in this instructable.
Apr 22, 2009. 2:14 AMprofpat says:
very simple and easy!! thanks for this instructable!!

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