This is an experimental project that uses aluminum cans to make decorative metal tiles for ceilings or walls by cutting open the cans into flat rectangles and using a die stamp to form them. This is similar to my beer can roof project except the die making is more complex here.
- First make a tile die design in expanded foam
- Then use evaporative (lost-foam) pattern casting to cast the tile die in aluminum.
- Clean up and shape the die with a grinder and other tools.
- Start cutting cans and stamping tiles
- Staple them into place on a ceiling, wall, or whatever you can think of.
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Signing UpStep 1: Make + and - polystyrene foam molds of die plates
Make some foam cutting tools if you feel like it, a good sharp utility knife will do OK on this step. This link has a great variety of foam cutting ideas:
http://wolfstone.halloweenhost.com/HalloweenTech/fotmak_MakingFoamTools.html
Polystyrene or styrofoam of some kind is carved into the shape you want to cast aluminum into. I used egg cartons, take-out containers, and dumpster scavenged foam. These foam pieces are exactly how the aluminum cast will turn out, so put some effort into this step.
First make two rectangular blocks out of the foam, about a half inch think and 8.25" by 3.75".
Print out a stencil or create your own for guiding and cutting a design on the 8.25" x 3.75" foam blocks. Here is this stencil link for use in Google Sketchup. If you make your own design, you'll want ribs of some kind as part of it to strengthen the tile. The templates I made have two squares which are the ribs. Cut the features into the foam very carefully with a sharp utility knife or exact o knife. The depth of the imprint should be shallow, about 1/16". A polystyrene egg carton is about the right thickness, a meat tray is too thick.
One foam piece should have an negative impression in it and the other should have the positive impression using egg carton foam (see picture). The two pieces of foam should have some wiggle room when assembled to make room for the thinkness of the aluminum can that will be pressed when the die is finished. You'll still need to clean up the final cast with a dremel tool.
Now finally hot glue on a foam sprue on the center back of the block; this forms a channel for pouring the molten aluminum into the cast. I used a 3" long piece about .5" x .5". In the pictures you'll notice two sprues/vents but these do not work, use a single center sprue.
http://wolfstone.halloweenhost.com/HalloweenTech/fotmak_MakingFoamTools.html
Polystyrene or styrofoam of some kind is carved into the shape you want to cast aluminum into. I used egg cartons, take-out containers, and dumpster scavenged foam. These foam pieces are exactly how the aluminum cast will turn out, so put some effort into this step.
First make two rectangular blocks out of the foam, about a half inch think and 8.25" by 3.75".
Print out a stencil or create your own for guiding and cutting a design on the 8.25" x 3.75" foam blocks. Here is this stencil link for use in Google Sketchup. If you make your own design, you'll want ribs of some kind as part of it to strengthen the tile. The templates I made have two squares which are the ribs. Cut the features into the foam very carefully with a sharp utility knife or exact o knife. The depth of the imprint should be shallow, about 1/16". A polystyrene egg carton is about the right thickness, a meat tray is too thick.
One foam piece should have an negative impression in it and the other should have the positive impression using egg carton foam (see picture). The two pieces of foam should have some wiggle room when assembled to make room for the thinkness of the aluminum can that will be pressed when the die is finished. You'll still need to clean up the final cast with a dremel tool.
Now finally hot glue on a foam sprue on the center back of the block; this forms a channel for pouring the molten aluminum into the cast. I used a 3" long piece about .5" x .5". In the pictures you'll notice two sprues/vents but these do not work, use a single center sprue.
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If you decide to go that way I would love to see your results (please share with the community)!
In regard to crucibles, I have no actual experience in this area myself. With that disclaimer out of the way, from what I've read about DIY metal forging and smelting one can make a pretty heat-resistant crucible from a metal container lined with a thick layer of refractory mixture that is 50% wood ash and 50% cheap kitty litter (bentonite clay), moistened with water to a paste and allowed to dry after application before being fired. Apparently, wood ash is well-known for its refractory and heat-resistant properties, and the clay acts as an inert binder. I've been told it can be used at least hot enough to forge steel (lining the inside of a BBQ forge), so you should have no problem with melting aluminum. You've got a really cool instructable here!
Check this site out. A guy I work with gave me a catalog from this company. They sell How-To books for just about anything you can imagine, including, making a crucible.
Then just press it with your vise and a breaker bar or make a press from a car jack. The car jack method would allow more pressure applied more evenly.
Either way like I said I do really like your project looks very cool, you could even paint them with some automotive paint and apply some clear coat.