Casting Aluminum in a 1000lbs Greensand Mold

[@tomiesto240]

You know a lot about the history of Aluminum in the 1800's, but have you heard of providing your guys with PPE? Silicosis is no joke lol

[@GarenPhillips]

Hi smartass, this is 120 grit olivine sand which is to heavy of a particle and it's not silica. It's harmless. And we do provide PPE, but it's more dangerous to wear because a splash of 1400 degree metal onto a mask will turn your face into a torch. This foundry has been around since the 1950's & my grandfather and father worked in this foundry for 50 years+ without issue. but please, tell the professionals what they are doing wrong. You clearly know more.

[@KGB95140]

Wow, I did not expect to see a video as complete and well explained. We learn as much from this video as from the thousands I have traveled to understand the process in its entirety. Good luck and success Garen and may your grandfather rest in peace.

[@JackwLarson]

It’s great to see all of the steps of the process in a pace that’s understandable. Also, the little factoids about founding fathers and etc are really cool! Thanks for posting, Jack

[@ryanburbridge]

What a great video!!!! Thank you for taking the time to post it ALL the notes were such an awesome addition!

[@Joniclem]

As someone who loves History, this was an excellent and informative video.

[@patlawless1960]

Thanks for posting this! I can watch this sort of thing for hours; any kind of metal or foundry work. Cheers!

[@theyhatedHimcuzHetoldtheTruth]

What a beautiful process. I hope when day I'll get on this level here in my small foundry. Your effort to make such a long and detalied video is highly appreciated!

[@rupert5390]

Best video on casting on the internet - fantastic historical referencing - also brilliant filming and cutaways to other work - may you prosper for q long time and god look after your business - many thanks.

[@Daviemes13]

Best video on youtube ever! Shows everything and also very educational ! Getting ready to do some sand casting this summer, first time since I was in school over thirty years ago. I hope your business keeps going in this very competitive world with everyone jumping ship heading to china for slave labor. Funny how prices have been forced up and now no one can afford to keep American labor employed since they have to pay such high prices for food,clothing,auto upkeep, insurance, house payments and or rents and they expect a laborer to now work at McDonalds for $8.00 dollars an hour and pay these exuberant prices on things. And I blame Wall Street and the banking industry along with our politicians for all this crap. Once again, Great Video!

[@richardjones1022]

A very cool process. I work in an old foundry as a Pattern Maker and a Tool & Die Maker. We use an oil sand that gets hardened with gas and our Core Makers stack the sand molds then clamps them together then casts them. Thank you for sharing this video with us.

[@Epyon3001]

Thank you so much for not only a great video about a cool process, but all of the history and background information as to how you got there and why things are done that way. Even your comment answers give details as to WHY that 1000lb mold is so meticulously made vs the smaller line in the background. Thanks!

[@fakiirification]

yup. 3d printers are amazing for pattern making. Im just a hobby guy doing stuff like this in my back yard. but a 3d printer has opened up all sorts of possibilities for both prototyping as well as final cast.

[@FloridaDIYer]

Wow! Very cool. I have often wondered how mold making and casting was done. This excellent video was very informative.

[@shawnramsay1851]

Hey Garen I am really interested in getting into making some small moulds and playing with making some castings. I have done this before in school we had to pour our gear boxs for our final year machining course and found it very interesting then. Great video thank you for sharing it with us! Waiting patiently to see a production 71 series blower case.......

[@markfryer9880]

Hi Garen, another excellent video, this time with an incredible amount of historic information on foundry work, aluminium and your own family history. I think that it is safe to say that I will have to watch this video several more times to fully take in everything it contained. I did note that this larger mold did require considerably more time and man power to produce than the smaller 250 lb ones did. Am I to understand that 3D printers can print directly in wax for the lost wax process?

[@GarenPhillips]

There are printers that print wax but a more viable method is HIPS material(Styrofoam). The benefit of 3D printed investment castings is you can control the in-fill of the print(how much material is inside). You can practically print a paper thin shell of the thing you want to cast, then just burn out the material. I have a Prusa I3 Mk2 coming in about a month or two and will be showing ho to do it. You can also print a Master directly and just send it to a matchplate foundry and they will make you a traditional pattern. We've been doing that for a few years now and they work great. If the part you are wanting to cast can be totally split down a plane with no pockets or valleys going into the other side of the pattern(think casting a bucket vs a sphere) then you can just superglue the two half to a plywood board and producing castings right then and there. They also have sand printers out that can create even more complex castings than HIPS/investment but they currently start out at 500k. Be a while till that's standard practice. There is one of them about 45 minutes from me, would be an awesome video to shoot.

[@GarenPhillips]

Also if this is something people are interested in I'll dedicate making a video directly explaining the history of patterns, match plates and aluminum foundries. Right now i have to focus on generating money to pay my bills though lol

[@gusbisbal9803]

Yes please, I for one would love that.

[@Len_M.]

Would it not be easier to just use a hydraulic press to pack the Sand and vibratory plate? Or would that still have a high chance of unwanted voids? I guess he did use a Press, but I mean for the whole process.

[@mattamiller]

Thank you for putting this video together. I'd like to learn more about casting and eventually try it myself, but It's hard to find good videos and information on the casting process.

[@TheRealCreepinogie]

Very good video and I especially liked the historical tidbits of information. You're not only interested in your business but passionate about the industry, how it came to be and where it's going. I see you're using an offset matchplate for that deep castings. Well done!

[@Boryca3]

Great stuff here Garen, big fan.

[@budapestprojectytc6002]

what is particularly impressive is how small this building is for such a huge production. I've been in a foundry in my hometown and the building is huge but there are no machines to help mold making. In despite of the size most of it is underused.

[@budapestprojectytc6002]

where can I get one of those David Bowie boots?

[@metalmogul4691]

No party working in that place but where else are you going to get that aluminum casting from. Hard work but well done.

[@josephspeciale9724]

Très belle démonstration du moulage en motte,beau travail "l'expert en étain"

[@bearbon2]

I really enjoyed watching this video. Great printed narration and history. - but damn, that's a noisy place to work! I assume that racket in the background is grinding and finishing but it would be nice to have it in a separate room or building away from the molding operation.

[@Gaark]

Excellent vid Garen, loads of info :D

[@Vikingman2024]

Absolutely fascinating ! Great history lesson also ! Thanks so much !!

[@typebin]

very educational and nicely captioned video!

[@ΒασίληςΒαλοπήτας]

Great job .Greatings from Greece.

[@tomharrell1954]

Nice work. Beautiful. i am sorry to see it go but things change. It seems you handle it better than I.

[@toddgillespie8165]

What's the cast? It looks like a pressure cooker/autoclave vessel.

[@mattamiller]

Do you know anything about casting iron?

[@euanreid6682]

Molten mental and just T-shirts are they crazy?

[@Cheers_Warren]

That was fun! Thanks for all the extra edits and notes impressive greensand casting at the very limit of the rotolift, I just sold my pattern shop where we still made all wood patterns with out cnc. In pa. But we were getting into cnc in house and outsourcing and the new owners have embraced it to as well as 3D printing . I did not know flask guide were only since 1978! Really ?? Cheers Warren Wdpattern co

[@frankstanton6972]

How do they make a profit? We could make twenty in the same time! The slowest moulding I’ve ever seen,

[@jackking5567]

Awesome video. Thanks for sharing with us.

[@wmsification]

Fascinating. After I watch all your videos, I'd like to contact you. I recently found myself in the aluminum casting business...

[@GarenPhillips]

Looks like i can't PM you for some reason, send me a DM here or on my instagram and I'll get back to you.instagram.com/GarenPhillips/

[@gusbisbal9803]

Garen, I have just discovered your video. I have been bingeing uncontrollably since finding them. The overlays, the notes, your ability to convey information in perfect context has inspired me to do my own youtube channel. Thank you Sir. Can I ask what Camera do you use? Are you using a stabilisation gimble? So you use adobe after effects for the notes?

[@TheFritz423]

Badass video. I am ready for the apocalypse.

[@48wilber]

Kubota: "We need 10,000 bell housings by June 25th",,, Foundry: "no problem June 25, 3087"

[@petersaupe7455]

I made casting for Kubota,in the bad old days.The foundry I worked in is flattened and the site is going to be a Lidl.

[@standardcake18]

Your robotic lambs sound sick.. Still really cool to see

[@sabo7433]

Hi Garen, I'm Saren. We've got nearly the whole alphabet on our team.

[@donschofield4849]

Great video .

[@nil233x]

Same basic molding process as we used in a cast iron foundry in the mid-1970s. That job bought milk for the kid but I sure hated it.

[@wantafastz28]

Cool video, keep it up.

[@megasmart1337]

Great video!

[@imysteryman]

I enjoyed this video a lot, thanks for sharing.

[@Proud2bmodest]

No need for patterns any more, the sand mold itself is printed in 3-D. www.voxeljet.com/materialien/sand/

[@WILDBEES_LATVIA]

Thank You for well made video with interesting facts.

[@timmyhoover4641]

Wow I made this piece myself, never had that much trouble making ,and twice as fast.year 2000

[@adamsonntag5755]

Good teamwork! It can’t be easy working in tight quarters like that.

[@russellprimm6649]

This guy is the real Iron Man :)

[@PursuitofSpeed]

I'm all about this pop-up video

[@kennedy67951]

That's some bull crap. The striker plate should have it's on clamping hold down built into it instead of using those bar clamps.

[@A3Kr0n]

Watching the two half's come together was almost too much to bear.

[@justinadams6447]

Thank you for shareing :)

[@AmalgmousProxy]

Ramming that whole thing by hand is out of the question.

[@alexa.davronov1537]

Really informative video about history. But precautions to working with molten metal weren't that nice.

[@saml7610]

All the facts and stuff you included in the video were great. I really enjoyed watching this. Ericdawg420 is a dumbass. Thanks for the quality video editing and thanks for taking the time to document the high precision mold making and casting process from start to finish. It was a long video, but I learned a lot. Additionally, I'm sad to hear that mahogany pattern making has become a lost art, but on the other hand, we're running real low on mahogany trees round the world, so maybe it's a good thing. That said, I'm sure we could figure out the process again if our industrial might were to somehow disintegrate overnight.

[@mannequingrin]

Are you guys hiring?

[@joestewart7487]

very cool

[@mayoropl1]

So, half of the time guys just fighting with battered and undersized machine? 2x4 shims, small cardboard pieces and wooden planks in beginning of pattern removal, "pattern can't clear the mold"... Am I right? Also frequent use of metal strips under front part of machine (guess because it's crooked)... I'm not telling you have to use only cutting-edge-technology and sparkling new machines, I'm just trying to understand what in this video part of normal work process and what is necessary just because of equipment limitations.

[@rosen9425]

Automaker Koenigsegg has been using 3D metal printing parts for their hyper cars since 2014. When you can print a complete turbo assembly in one go and bolt it directly to the engine you know you've gotten very, very far. Given the price of those cars it's obviously a niche market technology for a long time. Jay Leno uses the same technology for his restorations, by the looks of it he also has endless money on hand for that.

[@rupert5390]

Hey Garen two things - you pinned the idiots comments - for public humiliation I hope - also noticed you have 47K subscribers that is really awesome go for it man you need to take this company into the future and it looks like you are - your dad his brother and granddad would be really proud of you man.

[@GarenPhillips]

thanks man

[@milanthemilan5015]

OSHA left the chat.

[@wirabumi54]

Hi.. Garen, when I see the team work of these guys..it very possible one of them will lost his fingers someday.. especially when a guy put a wood below a half ton of green sand mold... I think you should find the other way to avoid that possibilities... I think if 3 japanes asign to do such job.. they will deliver better quality output with fewer time and more simple methods (sorry just to compare) but anyway overall video is good.. thanks I will thumbs up!

[@aaabeverages7152]

Cut my teeth on lost wax investment casting of PM's. I thought that was grueling until watching this.

[@dansmolen1618]

Nice job on a bitchy pattern! Good job men!

[@bradmccartney187]

Can you spot the safety violations. I see two guy's not wearing eye protection and I don't believe no one has hearing protection. I worked for years in an Iron foundry making molds and I can surly out mold the one guy in my sleep JS.

[@ericgossard9606]

Your an old lady. You better stay safe at home crocheting or something that wont upset you.

[@rodrigodiego6304]

God keep they mans safe! It is a job that be seem most dangerous to me!

[@adamadam-po3tr]

lost foam casting in algeria

[@EddieVBlueIsland]

Hum vibration absorbing rags - bentonite is kitty liter and oil dry.

[@frankstanton4712]

I worked in a foundry making all kinds of brake drums, this size and even bigger, we would have made twenty while these were makings This one! How do they make a profit. This is a complete joke

[@jasonleese546]

Yes defo not v productive the thing that made me cringe no vizers as a moulder for over 30 years I have seen more burns than I care to remember and anyone in my industry can tell you aluminium is by far the most dangerous molton metal anything from burns where ally sticks to your skin to smelliting plants being distroyed come on boys you only get one set of eyes 🤕🤕🤓

[@Brentiannoli]

buy a gimble for your camera. The instability of the video makes it hard to watch.

[@GarenPhillips]

don't have the money, best i can do is a cheap steadicam. I am building a mount though to turn my DJI mavic into a point and shoot cam which is 3 axis stabilized

[@bryanisensee2867]

That’s a 1000 pounds of aluminum? Possibly miss read what I was reading? Glad it’s over though, this video Damn near bored to shit out of me !! Lol

[@matthewprince6157]

you didn't have to watch the video. But based on the first problem I'm going to say you aren't that bright.

[@smallcnclathes]

I read it as 1000lbs of green sand.

[@tyroniousyrownshoolacez2347]

This is what happens when you don't educate yourself kids. You play in the sand 10hrs aday and call it a "skill " Learn 3d computer apps and go investment casting.

[@ericgossard9606]

You snot nosed, unappreciative spoiled bastard. These guys are makin things, while your pushin some buttons. Not everyone has had the luxury of being lazy. Learn to appreciate what generations before you have done to make it possible for you not to have to get your frail little hands dirty. Spoiled bitch.