ALL Ways to Make Solid Metal 3D Prints (almost)

[@PaulsGarage]

To get the course discount code, sign up to the mailing list here: paulsmakeracademy.mykajabi.com/joinus (coupon code: MAKEMETAL2024 good until jan. 2nd, midnight EASTERN time

[@hen3drik]

Hey, very nice mentioning me here! Glad you used my most recent content, that was quick! 😊 thank you 🎉

[@PaulsGarage]

Thanks for stopping by! i love your work, it looks awesome!

[@MikelNaUsaCom]

There are also lots of other material out there to cast besides metal, if you don't want to deal with too much heat, you can cast wax, plastic, resin, or epoxy. I made a few epoxy casting of a pig for my sister's grandkids and they loved them, as gifts and non-toxic toys... and those casting could be used as molds for sand casting as well... just throwing out there that there is a big wide world of materials besides metals out there... I'm liking aluminum at the moment, but that zinc alloy is looking kewl as well. Happy Sunday!

[@AnWe79]

Exactly, one of the lowest bar ways to get into casting is soap or candles. You just melt the wax/soap on the stove or in the microwave. First thing I cast from a print was a miniature Fight Club soap bar (printed positive, then open face cast in silicone negative).

[@luciyer4345]

I miss Makercise too. Watching him build the gingery machines true to form was really a masterclass and it was what led me to your channel as well. Cheers!

[@jerrysanchez5453]

Imagine being able to say you made something that's in display in the Smithsonian. That's pretty cool

[@robbbert229]

Wow, another paul video within the same month???? Very nice!

[@PaulsGarage]

I think I got 4 out between december 1st and now. Thats gotta be a record!

[@lundgrenbronzestudios]

Thanks for the shout out! My last project was lost foam casting. I can’t say I’m a fan of it.

[@PaulsGarage]

I wonder if there is a specific foam or sand or something used in industrial lost foam casting? It must be designed to burn away without all the ashes, and somehow not get sand washed in there, too. Seems like ceramic shell is just the way to go

[@ironhead65]

Great high level touch on the wide variety of options!

[@PaulsGarage]

so many options, so little spare space in my garage/schedule!

[@andrewatchaboy2762]

A good way to cut down on plaster costs for lost wax is to use normal PoP mixed with sand (Quikrete white silica play sand is pretty great) and water in a 1:1:1 ratio using the typical preparation steps (mix materials together, vacuum bubbles, pour into mold, vacuum again, etc). Using a vacuum table with even just solid flasks, you can get some seriously impressive results and a bulk bag of plaster is only like $20-25 at dome depot.

[@andy-in-indy]

The big thing that excites me is using ThermoCast to cast a Zamak mold for plastic injection molding. Super fast turn around and recycle the bad/worn metal molds.

[@armorhide406]

Oh yeah, I remember seeing the replica door when I still lived on the East Coast. It was awesome seeing your name on the plaque

[@PaulsGarage]

that's awesome! i still haven't had a chance to see it yet

[@tinker-craft]

Great overview of different casting methods! 👍

[@PaulsGarage]

Thanks! I've got a ton of ideas for future videos.

[@JonMurray]

Just binged a load of your casting videos today then this popped up! Thanks man!

[@PaulsGarage]

perfect timing! thanks for binging 👍

[@anon_y_mousse]

I miss Makercize too. I don't think he ever finished his Gingery lathe either. I also watch Black Beard. Sounds like all of you guys watch each other or something close to it.

[@dfross87]

He finished the Gingery lathe and shaper. Put out one video about starting the Gingery mill project (5 years ago), then vanished. Published one unrelated video nearly 3 years ago, and that was it.

[@brown56765]

I love the unattended shirt! My mother-in-law got me the same one for Christmas!

[@brown56765]

*unsupervised

[@3s-Woodworking]

What about using hips filament and limonene for smoothing.

[@slay3r1452]

I also miss makercise. Underrated channel and good content.

[@blahblahblahblah2933]

Kelly Coffield (on youtube) seems to have a really good work flow for lost foam. I'm not a super fan of the process, but he makes some really impressive engine parts using the technique.

[@PaulsGarage]

That's the guy I was trying to think of!!! I couldn't remember the name, thank you! There are ways to get good results out of each process, it's all practice and technique. Maybe I'll check out his videos some more and give his methods a shot

[@odellcreations]

@@PaulsGarage his method is a lot like investment casting. He blends the two methods of lost foam with investment slurry and use a vacuum assisted furnace to pour those castings. I don't think I would call it traditional lost foam casting and that is why he gets much better results than most do with lost foam. Lost foam can produce professional results with the right equipment and know how.

[@roscoepatternworks3471]

For lost wax, the molds can be made from plaster or i use Durham's rock hard. Duplicating simple patterns, I use plaster molds. And then squeeze bondo for the duplicate patterns. Depending on what you're making, there's no need to print anything.

[@odellcreations]

@@roscoepatternworks3471 absolutely. I have seen this method used quite a lot.

[@stevesrt8]

@@odellcreations he uses a professional coating. same stuff they use in industry. Engine blocks, Motor housings all kinds of stuff are cast that way. Its a very good method of casting. i do lots and very pleased with my results. great for larger castings. stuff you cant print or ram up in a sand mold.

[@asdf154]

Nice overview! Think you could add timestamps?

[@AlitaGunm99]

Don't forget sinterable filaments!

[@sirukin7849]

Can you look into using portland cement and silica sand moulds? I picked up some Petrobond sand, but I'm thinking that using portland cement mixed with silica sand would work quite well for making molds. Edit: I am aware that people believe that portland cement will spontaneously explode, however you can mix your own refractory cement and cure it in an oven to remove any trapped moisture. You likely wouldn't get that many pours with it, but compared to using petrobond sand it might be less work.

[@thefallenone7988]

That's what I'm here for, Paul.

[@PaulsGarage]

awesome!

[@wolfwind9658]

Ya the electroplated stuff isn't a whole lot stronger than just printed. But it is great for props.

[@oohshiny8713]

Breaking Taps did a video on testing the strength of plated 3d prints a few years back. You can electroplate (or strictly speaking, "electroform") onto almost anything you can put conductive paint on - wood, plastic, leaves, etc. Peter Brown has done a number of videos on it.

[@odellcreations]

Glad to see you putting out some videos again that aren't 3d printer reviews. 😆

[@PaulsGarage]

Me too! Thing is, i didn't have time to make any videos lately. The printer reviews at least had a deadline to get me off my lazy butt 😅 I think printers are the best gateway maker tool, more people should get them

[@odellcreations]

@PaulsGarage certainly an addictive tool for makers.

[@Liberty4Ever]

I thought this was going to be one of those technically interesting videos that wasn't practically useful for me. PolyCast filament is interesting and I might have a use for that, but ThermaCast resin is very interesting. I like to cast my own bullets. That typically means I'm buying commercially available mass produced bullet molds and that's usually good for the regular job, but I like to play in the margins with shooting science, where there are no commercially available molds for the weird stuff. A couple of high end bullet mold suppliers will make custom molds to the customer's specification. I'm surprised they can do this for the very reasonable prices they charge for custom CNC machining, but the prices are high enough that they're not conducive to iterative development to optimize a design. With ThermaCast, I can resin print my own molds the same day, test the results, rinse and repeat. ThermaCast brings the iterative rapid prototyping that 3D printing is known for to metal casting. It's not just good for lead, either. Zamak casts at 425 C, well within ThermaCast's 550 C limit. Forget boolits! I'm making GUNS! 😀 Actually, I heard 3D printers are already pretty good for that. 😀