how to cast a DIY casting flask (Modular Flasks part6) casting V6.7 with 3D printed gate & spin trap

[@morgansouetre9968]

Hi, your design is really cool ! I started to mold my flasks three days ago and it works very well. I already cast three of them. I noticed the feeders are really big, that's why I simulate it on "NovaFLow&Solid" and I found you only need to fill 25 milimeters of it. I think your filling system is really good for exceptional quality flask, but if you make bigger runners and gates you could heat really less your aluminium, and you could save more sand and gaz. I started design a connector to attach two flask and make a longer flask. I'll share it later ! Keep on it !

[@JulianMakes]

awesome Morgan!!! i'd love to see some photos, i know others have made some too. I'm so pleased you've found it useful! :)

[@JulianMakes]

How did you get on Morgan?

[@WarGrade]

I turn my back for 30 seconds & you have 3 videos go up, be watching the next one tomorrow. it's looking so good now Julian

[@JulianMakes]

War Grade thank you mate! It’s all coming together :)

[@danharold3087]

Love it. You have already demonstrated the feeders are needed. Great work.

[@JulianMakes]

thanks Dan, you'll be interested in part 7, i do the same but with NO FEEDERS! (eeeek!) :)

[@ChatterontheWire]

As always thanks for sharing along the way on this one! Can't wait to see what ends u being the final one, completely assembled.

[@JulianMakes]

cheers Chatter!!! that is very kind of you!

[@Jack_C_]

Absolutely love your enthusiasm and what a great result. Job well done. 😄

[@JulianMakes]

thank you so much Jack :)

[@paulriggs42]

Excellent results !

[@JulianMakes]

thanks so much Paul!!!

[@garygenerous8982]

Julian, I legit started clapping and cheering IRL when I saw the reveal. Those look awesome!

[@JulianMakes]

hahaha your comment made me proper lol IRL. i accidentally i woke my wife up (she wasn't amused lol) - thank you so much Gary!!!

[@hemeoncn]

Well done.

[@JulianMakes]

thank you Clarence :)

[@juho6837]

Good pour👌

[@smallcnclathes]

How weird is YT? This video was just recommended to me under the "Woodwork" topic. The wonderful ways of YT

[@blitoris]

I'd be well chuffed with those results.

[@JulianMakes]

thank you Khane!!! i really am :) wait until you see the next one (no feeders!). it should be uploaded in a couple of hours (my internet is so slow)

[@tobhomott]

Amazing! Hope the no feeders version works out, the assembled flask should be easy enough to square up with a little sanding as you say, and maybe a shim or two to eliminate any wobble. 👍

[@JulianMakes]

Thank you so much Tobho! Yeah i hope you are right and it's not too fiddly :)

[@raschellesherwood6347]

Looks great mate good work. Bloody fantastic. Those feeders seemed to work great. Always use feeders as good practise. Metal as you seem shrunk 7mm I think you said on the longer or the two casting.. if you didnt have the feeders there is a big chance they will end up with cracking because the metal shrunk and cooled too quick.. and or corse distortions where applicable... again looks awesome and keep casting mate your doin awesome

[@JulianMakes]

thank you so much Raschelle :)

[@askquestionstrythings]

Nice pour, the spin trap, runner, gate, pouring basin, and tapered sprue predictably made an improvement in your surface finish and casting quality. Chvorinov's rule will allow you to calculate the solidification time for your casting. (surface area and volume are the major influencing factors in solidification time) (hint: you can also use Chvorinov's rule to calculate the size of the feeders to prevent shrinkage via the basic relationship "Chvorinov's rule for part < Chvorinov's rule for feeder" so you have 20% longer time in the feeders) Your pouring basin could have been a little deeper and the ridge closer to the bottom of the pouring basin. Look forward to seeing more as you refine this.

[@JulianMakes]

thank you so much Ask! i've been watching your channel recently, great fun experiments. :) and thank you for the casting tips and advice, it's much appreciated!

[@askquestionstrythings]

@@JulianMakes thanks for watching, and your welcome.

[@OldIronShops]

It's always best to let it cool in the mold less stress in the part from rapid cooling.

[@JointerMark]

A fantastic result! The casts look great. If you make the side ribs too narrow will it be hard to register the cope and drag when you stack them one atop the other?

[@JulianMakes]

thanks Mark! yeah i'll def not go to just a pure plate. but i've done a prototype where the ribs are even smaller (and the wings - and they have bolt holes cast in too) - it's a future casting

[@FloweringElbow]

Hi again Julian. I got excited watching you opening up these bad boys. Knowing what it's like to attempt a new pour I can almost feel my heart beating faster. Fun to watch! Right now I am making patterns (wood) and prepping to cast some CNC parts (the z carrage) which are longer and heavier than anything else I have done (it's to be a big 8 x 4 monster cnc). I like the gateing and swirl trap system you used. I 'think' I will need gates a touch larger for the casting I want to make to get all the metal in there before freezing... By your accent I am guessing you might be in the UK? If so, at some point we should totally do a YT colab of some kind. Ok peace, Bongo. PS, how do you think you could eliminate the bending (do you just put it down to the geometry of the pattern (the two perpendicular ribs)?

[@JulianMakes]

Hi bongo! Ive actually been a subscriber of yours for quite a while! Yep im based in suffolk. Ooh id love to have a big old cnc. Ive just got myself a lathe. Id love to do a collab one day! Only after covid though, its playing hell on my free time right now :(

[@PaulOvery001]

Spotted "Wow Things" using beach sand mixed with molasses. Small details can be pre-hardened with a match or the whole thing can be warmed a bit before turning. Go on the experiment!

[@JulianMakes]

thanks Paul!

[@swdweeb]

Hey, where did you get the idea for the runner/gate system? It's brilliant! 😄😄 Just curious, what was the ratio of gate to runner? I assume your gates were more volume. Well done mate. A joy to watch. You're a prince... well not like Andrew but you know what I mean 😄

[@JulianMakes]

thanks Perry :p yeah my sprue is 51mm2, the runner is about 52mm2 and the two gates i purposely made very flat and wide (way too wide really ) but my thinking was to keep the area cooler - each gate is 3mm x 24mm (so yeah the gates were not the bottle neck :) i love it. Did you like my little runner extension pieces? :)

[@swdweeb]

@@JulianMakes I hadn't thought about the gates cooling the metal. Although once the sand is heated, I'm not sure how much heat loss there is. I was thinking more along the lines of lowering the velocity at which the metal enters the parts. You're at about 2.8:1 in terms of the gate to runner volumetric ratio. Which, if I do the math right, should have slowed the velocity by about 2.8 times ;-) I did like the runner extensions.

[@JulianMakes]

@@swdweeb lol you are a math genius :) i was trying to keep the gate area sand as cool as possible (where the fresh hot metal keeps topping up the heat). i should do an experiment where the gate is just s square 5x5 to see if anything's different. (if i didnt have other stuff to do right now ;p)

[@jerrywhidby.]

You forgot to add "And Epstein didn't kill himself."

[@swdweeb]

@@jerrywhidby. Wait...what?? You mean he didn't? 😉

[@royscheirer5855]

I've used square nuts and printed them into the part so permanent.

[@JulianMakes]

very clever!

[@lajostoth2846]

Very professional design and execution, congratulations! Where can I download the printable design of the vertical inflow system (.stl) ?

[@MtnDan-d4g]

I ended up having to cut the fingers off. I guess different printers, different results. Hot glue works just as well for me. It's a strong bond and it's easily removed when finished. I redid a couple pieces in fusion 360 to remove the fingers and slots. I printed those with great results.

[@JulianMakes]

Lienad Abrasax ahh interesting and thanks for the hot glue tip. You’ve reminded me, I was going to release a glue together version, I’d forgotten. I’ll sort that out ASAP. I hope the rest works out for you! Cheers

[@charles1379]

should consider making an infill piece to fit under the wings so you do not have to dig out the sand every time you are moulding up.