I've only done this process a handful of times, and by no means am an expert. I've never tried polyurethane foam, but I've heard it does not dissolve as quickly as polystyrene (may need some trial & error). I haven't done any big parts. Highly recommend a pressure-head tool though especially for a large part (a link is in the description). There is a brief time when the foam melts before filling out the mold where a reservoir of metal is essential for a continuous pour. Best of Luck!!!
@jarikcbol
11 жыл бұрын
Your video told me just what I wanted to know, which was how detailed a piece can be made with lost foam casting.
@JackWilson327
11 жыл бұрын
Thanks for this! Pink foam is rigid cellular polystyrene. I'm seeing expanded polystyrene (EPS) as the norm. The original lost foam method does use a refractory plaster coating. It's applied by dipping the foam in a plaster or spaying it on. Gypsum mud seems to be ok for aluminum. Alternate processes use a thicker plaster and then a burn out / firing like lost wax. In the original process the plaster coated foam is supported by dry non-compacted sand. The plaster yields a much better finish.
@joycetheeditor5990
7 жыл бұрын
Nice video. Very clear illustration about lost-foam casting.
@JohnGrimsmo
12 жыл бұрын
Very neat, it's nice to see the process in action, I've only seen bits and pieces elsewhere.
@jarikcbol
11 жыл бұрын
thanks for the information. His video did show me that a level of detail greater than what I expected can be achieved, so it was informative.
@kjohn919
11 жыл бұрын
Do you even mill, bro?
@whiteraven886
9 жыл бұрын
Sorry about the unfriendly comments, but there are some good points. Casting is always tricky. I work in gold, and aluminum doesn't have the same mass. Using a can or something to act as a reservoir of hot metal is good perhaps, and you mention this. But the comment regarding a plaster coating of the foam seems to be a brilliant solution. Oh, and screw that guy who busted on your biceps, You're beautiful. (Yeah, I'm a dude! :-P )
@nesabrdza6548
5 жыл бұрын
Hallo, with what did you mix the sand, only with water or there is something else ?
@hamzatariq5396
5 жыл бұрын
its 90% sand 3% water and 7% clay or resin
@halfway2hell
9 жыл бұрын
Have you tried this method with cast iron? If cast iron won't work with foam how about PLA plastic? that has been 3d printed? Great video tutorial by the way.
@ThisIsToolman
11 ай бұрын
Do I understand that simple damp sand was used and not green sand?
@metalwreck450
8 жыл бұрын
I like the setup. Is the casting bucket and furnace homemade? Typically in these setups they are homemade but they're real nice looking and are working pretty nicely as well.
@almutanabi1000
8 жыл бұрын
I'm sure non of these castings came right ,
@davemisme
11 жыл бұрын
get joint compound and make a very thin viscosity soup. dip your foam into the soup almost like dipping candles. build up a shell. DRY COMPLETELY. the foam inside will create the shape, the hard shell will prevent blowouts of the sand as the foam melts and before the metal will fill the void.
@dumbcat
8 жыл бұрын
I hand crafted a prototype sculpture out of wax. I do not want to destroy the prototype. I was thinking about making a reusable mold around the prototype, then pouring some kind of liquid foam into the mold. That way I can destroy the liquid foam sculptures many times during the lost foam sandcasting process, to make many copies of my original wax sculpture, as I can pour many liquid foam sculptures. Question... does anyone know of a suitable liquid foam I can use? By liquid foam I mean a foam you can pour into a mold, and the foam hardens. Thanks.
@kerokero_furogu
8 жыл бұрын
if you have a wax prototype, then lost wax casting is a great method. It requires a bit more effort than this, though.
@terenfro1975
11 жыл бұрын
I would take your process and modify it closer to the lost wax process. Coat your foam with a plaster. Let it set. Then cook out the foam while curing the plaster. This will prevent the gas blow back from the burning foam. Great video.
@_AmitKumar_
Жыл бұрын
Rare video of this process
@tartredarrow
11 жыл бұрын
Sweet. This looks like a good way to make a receiver for a .22 Rifle.
@maximilianlindner
11 жыл бұрын
Are you advertising your biceps or mold casting? ^^
@JackWilson327
11 жыл бұрын
By the way. There's no normal on casting methods. Whatever works, works. The key seems to be tweaking it to work the best for your part or process constraints.
@zhigangxu2007
Жыл бұрын
What kind of sand do you use? Just ordinary sand?
@Navigator777777
10 жыл бұрын
Ha! I have the exact same metal melter! It sure works exceptionally well! I owned a $65K 3D printer that produced plaster parts. Not a very good investment. As a hobby caster....it seems the three important things are: sand, sand, sand. Using Match Plate system like our father's is not a bad way to go either...especially with the ability to perfect match plates. Cut half the model in foam or wood or plastic and simply pull it from the mold. That is .... unless you are after the under cuts. I'd go with a much bigger sprue. Still...it was a nice effort!
@billsalvey
10 жыл бұрын
my question is, you have a cnc mill...why didn't you just mill the product out of aluminum to begin with instead of wasting time doing it the way he just did it?
@fraserdavidson6900
9 жыл бұрын
Cnc mill would take longer than casting, due to limited feed, and cut rates. Believe it or not, casting is the fastest way to produce complex metal shapes. Machining is a very slow process, and is expensive, but both have their place.
@billsalvey
9 жыл бұрын
true
@male1991
3 жыл бұрын
Loved it. I got here looking for Full moulding (Cavity less casting). It's the same right ?
@shershah9406
2 жыл бұрын
Thank you. Can this be used for ferrous metals ?
@danielsg2251
11 жыл бұрын
Dear Brian. The same process works with Polyurethane foam? do you have another videos with large samples ? thanks in advance.
@weistrass
4 жыл бұрын
Nice protection kit, did you buy it in Toys "R" Us?
@oldschool1993
5 жыл бұрын
No need for a milling machine- you can 3D print a mold in plastic, cover it in plaster, burn off the plastic and pour your part. This is even an interim step in the manufacturing process, as 3D metal printing eliminates the need for any casting at all. 3D metal printers are rapidly coming down in price and within a short time they will be within the reach of small shops and home hobbyists. This will make CNC mills and lathes as obsolete as shapers.
@tonyhill8300
3 жыл бұрын
no it wont
@oldschool1993
3 жыл бұрын
@@tonyhill8300 1895 Blacksmith with foresight- " " Those velocipedes are gonna run us out of business" Blacksmith with limited foresight "No it won't"
@tonyhill8300
3 жыл бұрын
@@oldschool1993 still plenty of blacksmiths about and still a good call for them
@oldschool1993
3 жыл бұрын
@@tonyhill8300 Yeah right- about 0.01% of what there were in 1895.
@levettp
4 жыл бұрын
100 x more useful than 3d printing
@rseleem7899
11 жыл бұрын
great work ... can u tell me what is the best method of molding the holes of oil and water for the engine blocks?
@iqinsanity
3 жыл бұрын
I known it’s 7 years later, but for anyone reading this, you don’t cast oil holes you drill them. As far as water jackets, you don’t use the sand method on the foam use the slurry method. Where the foam is dipped in a slurry that can flow in the voids of the foam you made for the water passages. Watch a video specifically about engine casting from lost foam.
@مريَم-ط5م7غ
3 жыл бұрын
Thanks
@harrypalmer5890
4 жыл бұрын
What about bronze?
@davemisme
11 жыл бұрын
got a link to a 3D printer that uses cast iron or aluminum ?
@jimidee100
9 жыл бұрын
Check out the Arts and Crafts stores for ready made foam items. One of my friend made a skull from a foam halloween skull.
@Benivator2
11 жыл бұрын
Why not just cast a solid block and machine it if you have such expensive equipment?
@alexw6225
10 жыл бұрын
I'm assuming this was for the purpose of demonstration.
@NoorquackerInd
9 жыл бұрын
I think it would be way too strong
@Benivator2
9 жыл бұрын
Noorquacker Ind. Right! That's how race engines are made, if i'm not mistaken. Not quite sure why machining a solid block is stronger.
@Benivator2
9 жыл бұрын
***** Where was this?
@alfeovaldez8066
7 жыл бұрын
Nice video
@mrslbroo2394
4 жыл бұрын
foam casting chamical ditels plz
@ctprjcstv3998
5 жыл бұрын
You should watch VOG channel on KZitem
@12erdude
9 жыл бұрын
Seems like this was for a class project. Seems highly rehearsed and he looks very uncomfortable.
@zerosk2
11 жыл бұрын
type of sand?
@sylvanenergy
10 жыл бұрын
what a shame to use a milling machine for such an object.....sigh
@alfteck
11 жыл бұрын
still foam is naturally porous where wax is not.
@runaway2074
8 жыл бұрын
bad resulte
@cnvw974
8 жыл бұрын
Stop wearing boots I've you should ever get some molten on foot, you will be in trouble! Best tip one have me. I started wearing tennis shoes and guess what? One day had a spill and I was able to kick shoes off before pain!!!!
@tonyhill8300
3 жыл бұрын
NO buy welders boots , they have a quick release pin so you can get them off real quick
@ldwithrow08
7 жыл бұрын
Those fumes from lost foam casting have GOT to be horribly toxic.
@ftrikerfox
10 жыл бұрын
goes to should expensive machinery vs common sense the common sense works
@jreedmcu1
11 жыл бұрын
just use a 3d printer
@gadaadhoon
3 жыл бұрын
This is a tad cheaper.
@tonyhill8300
3 жыл бұрын
a better method is to coat the outside of the foam with a "shell" of plaster of paris, just brush it on. give it a couple of layers then melt out the foam with a blow torch, takes a little longer ,but you have a much higher chance of getting a usable casting. Really this video is wrong on so many levels.
@milan2499
8 жыл бұрын
He almost looks lije faze censor
@vergeltuble5497
3 жыл бұрын
😮😮😮😮
@NafisAhmed-sp9vg
6 ай бұрын
Very bad casting product
@researchandbuild1751
6 жыл бұрын
So much misinformation. Stop using green sand with lost foam. Stop pounding sand. Lost foam, make the foam part. Coat it in plaster of paris. Embed foam part into fine dry sand. Add riser and tube to form a pressure head. Pour molten metal. Pull out perfect and clean item
@mxupersonal6017
5 жыл бұрын
Exactly! Process in the video is called "full mold".
@tonyhill8300
3 жыл бұрын
@@mxupersonal6017 or shell moulding
@dingusmcgee7948
9 жыл бұрын
mmmm no vent?
@metalwreck450
8 жыл бұрын
+Dingus McGee With lost-foam casting, the sand and foam itself are the means to vent gases. The reason to use sand only with a special coating on the foam is to allow gases to escape between the semi-permeable parts of sand. Plaster is not porous nor ductile so before warping or compacting/loosening, it will just crack. The easiest way to understand this is to keep in mind that sand piles UNTIL you use water to hold it together. However, the moment the water is gone, the sand will fall apart, because it never binds together, it just loosely holds together and can easily be pushed aside by escaping gases. Lost foam casting primarily loses points in that the foam negative itself is consumed whereas something like Lost Wax you can recover the wax, and make reusable molds as well using materials such as various plasters.
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