This Instructable shows how to take a 3D slice-form model and produce a solid metal casting of the object. It combines digital design using 123D Make
with traditional metal foundry techniques.
Slice-form modeling is a technique to produce a 3D object as a series of layered slices. In this case, I use a CO2 laser to cut the individual layers from foam to create a pattern. The pattern is then used to make a resin-bonded sand mold for metal casting.
AutoDesk 123D Make Software
Access to a CO2 Laser (I use TechShop)
EVA Craft Foam - 6mm Sheets
Glue or Double Stick Tape
Sand mold making materials
- 100 mesh sand - approx. 120 lbs
- Resin binder and catalyst
Access to a foundry to pour the metal
Angle Grinder with Cutoff Discs and Wire Brushes to finish the piece
I made it at TechShop!
All of the digital fabrication in this Instructable was produced on an Epilog Helix 60W CO2 Laser
at TechShop in San Jose, CA
The sand molds were produced at the Mission College sculpture lab
and the casting took place at the San Jose State University foundry