This lost-foam casting will be a little bit harder than my usual projects. It'll be huge aluminum casting of a thing with a very complex shape - clothes hanger. Yes, I know that coat hanger doesn't sound as something very complex but if we think about the shape than you can understand why it's hard.
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Step 1: Making a Pattern
To make a pattern I will use polystyrene sheet. To cut the shape of a hanger I'll use my new hot wire cutter.
Step 2: Making a Mold
Making a mold using lost-foam casting technology. For this process I need a flask, green sand, foam pattern and a lot of time.
Step 3: Casting Aluminum
When aluminum is melted it's time to cast. I had a leakage but it's not a big deal.
Step 4: Sanding and Final Result
This clothes hanger looks not bad after sanding though I had some problems during casting and had to use all 4 risers. I understood that I could have some problems during casting of such thing and that was the reason why I've made 4 risers.