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.

Materials List:

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

Production Notes:

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.

Step 1: Selecting the 3D Model

Using 123D Make, open or download a 3D object model to use for the project.

You could also use 123D Catch to generate the model from a real-world object and then load that model into 123D Make. In that case, it would be beneficial to use the Shrinkwrap function to simplify the overall model.
<p>it is a good job.</p>
<p>That is amazing, such a great way to combine the laser and metal casting to make those fine details. I really love the result looking at the side profile</p>
very cool, got to try this at home...

About This Instructable




Bio: I am a mixed-media sculpture artist from San Jose, CA. From an early age, I have enjoyed tinkering and building things and this serves as ... More »
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