Turning a 3d print into metal - Metal Casting - Lost PLA

In this video I will make a really cool skull mask designed by artist Zane Rogers. I started by 3d printing it using a plastic called PLA. Next I coated the 3d print in a special ceramic slurry called Suspendaslurry. After that I placed the shell into a kiln and fired it at 1500° F to turn them into a ceramic. I filled the shell with bronze consisting of 92% copper and 8% tin. Once cool I broke off the ceramic shell molds to reveal the casting.
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Casting equipment
PetroBond amzn.to/4bZJqsJ
Crucible salamander amzn.to/4eo1vSW
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3d printing FDM
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3d printing Resin
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Belt Grinder
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Welding
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Prime Weld machine amzn.to/3KMeXCQ
Metal finishing tools
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General
Wilton bullet bench vice amzn.to/4ckifIV
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Loc-line shield amzn.to/45v7Nfx
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Some of my favorite tools of the year
Makita Blower amzn.to/4c43LNK
Mini circular saw amzn.to/3VnWykp
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Camera Equipment
Canon 6d II amzn.to/4erxUbi
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All of the links above are affiliate links. This means that, at zero cost to you, I will earn an affiliate commission if you click through the link and finalize a purchase.
Find Zane Rogers work here:
www.myminifact...
/ trajan19901

[@robinson-foundry]

If you're interested in any of the tools or equipment I use and you want to help support the channel then don't forget to check out some of the affiliate links in the video description. Thank you for the support!

[@user-qf6yt3id3w]

You can imagine archaeologists digging this up in a 1000+ years and having endless arguments about how it was made. I like the liver of sulphur, polish and varnish to make it look aged.

[@tahahaider5836]

They'll just watch this video

[@user-qf6yt3id3w]

@@tahahaider5836 There's no way this civilization survives 1000 years without a reboot that takes out KZbin videos and probably almost all tech too.

[@tahahaider5836]

@@user-qf6yt3id3w it'll be available in the depths of an archive somewhere

[@PaulsGarage]

I was an archaeologist for about 6 years so I can tell you for certain they will shrug and label it "ritual object". Anything you see labelled ritual object just means the archaeologist doesn't know what it is. 😂

[@tahahaider5836]

@@PaulsGarage hence the generic labeling

[@erikig]

The Robinson villain arch is shaping up nicely 😅

[@HagendazPVP]

What an amazing piece, it looks like it should be in some sort of Aztec display at a museum.

[@Nobe_Oddy]

that came out BEAUTIFUL!!!!! and I LOVE how you use the patina to really highlight the design well at least it will look good as a decoration if you're never able to make it stay on :)

[@smartengineer2661]

Great result! 😍 It may be more practical to use 3D printing with anodizing for your mask. Where before anodizing it is critical to coat the mask with a graphite mixture (for electrical conductivity of the surface).🙂

[@Tyresio12]

You mean electroplating? Anodizing is a different process.

[@andreipendle1778]

Simply amazing. You knocked this one out of the park! Also good to see you putting your face out there. Your videos just keep getting better and better.

[@0l...-]

Incredible! Usually in casting videos you can see the not so pretty details, but here everything is perfect.

[@bigv6724]

That's freaking awesome and never seen that ceramic casing method before. That brought out so much detail in the mask it's unreal. A thinner mask would help i imagine and keep the current as a shelf queen show piece. If not maybe wearing a sturdy hat or rather helmet and attach your mask piece to that creating a samurai look. I can't wait to see a second attempt with a thinner build so you can actually wear it comfortably. I really hope other melters or casters see this video and try that ceramic modeling method. Some of the content creators make some really cool casting but can't achieve this kind of detail using just the sand.

[@smithdesignwerx]

I would add the mask to a helmet i.e. medieval or fantasy helm. BTW love the rapter claw I bought from you, hope to see more of your creations for sale.

[@00Discourse00]

Just wrote the same suggestion, scrolled down and read your comment. I was thinkin' a Kabuto with horns would be appropriate.

[@miketruby5983]

honestly, I feel like something like that would be best served if it were attached to a medieval helm of sorts, Maybe some kind of chainmail hood? just an idea. Beautiful piece

[@justinbanks2380]

Simply amazing. The processes you use are always fun to watch and learn from, but this one looked simply stunning when you removed from the sand blasting cabinet

[@projectdirtbikes]

That thing looks sick! It'd be funny if you hid the ceramic shell scraps with the design embedded in them near where old native pottery had been found in the past. Probably throw some people for a loop

[@Electric.overload]

That glove trick was probably the coolest transition I’ve ever seen👍

[@brandt-heiss]

That mask is so impressive... 😮 Beautiful.

[@Kamal_AL-Hinai]

First time seeing the face behind all this genius work

[@Skylanders_Fun_Facts]

It looks like one of the masks for Scorpion from Mortal Kombat and I love it

[@markhorvat4430]

A ball end or spherical burr would leave you a much smoother surface. The straight burrs are good for removing material quickly, but it’s easy to dig in too much and leave “ridges” near the tip of the tool bit. Just a helpful tip from a fellow friend of the details 👍. Keep it up, I love that when watching your videos, you can really see the evolution of your craft from the first to the last.

[@zohircherifi5616]

Impressive the mask ended looking like a meseum peace

[@MrDoItAll956]

This is freaking amazing I always thought 3d printing was impractical and was only for making toys but you have definitely made me rethink in how I see 3d printing

[@slothywoth6128]

Great video as always

[@emailjustinbyrd]

You haven't even had the time to watch it weirdo.

[@Owen-rl6bw]

yup

[@PaulsGarage]

Thats so cool! That looks amazing with the liver of sulfer and polish

[@ElDJReturn]

Very cool, reminds me of Mayan skulls. Also your videos have been getting better! Keep up the good work!

[@DaveyBooBoo]

Didn’t know about this casting method! Amazing design

[@samuele279]

Nice! The shrink is likely due to insufficient metal supply to the piece. Larger gates would ensure your piece has enough metal to draw from when cooling, if the gate solidifies before the piece it’ll shrink on itself

[@Btas4life]

Could always attach it to a custom motorcycle helmet, since it wouldn't stay via straps alone. Great work on the details on the bronze, ancient, atlantian looking mask.

[@Lol_Pig]

Scorpion from MK would be proud!! Very cool

[@DrihunGaming]

you can use a kitchen sieve to pour on the silica faster and more evenly. get one roughly the size of the box and get the full coat needed with only 1 passing per axis rather than several passes per axis. edit after rereading my comment, who cares haha. if it works for him then keep doing what you do

[@quixoticjedi942]

You need to make a matching head/helmet for it, that would make a awesome display piece.

[@luiznogueira1579]

Fantastic work! The mask looks really awesome. Too bad it turned out to be too heavy... Maybe you could make a matching helmet or skullcap to support it?

[@LunarburnStudio]

Fun project, Amazing the difference Fused Silica makes.

[@josefmildner7665]

Amazing! Such a craftsman 😁 great work!!

[@Druforithe]

OMG! That is SO beautiful!

[@sketchi7472]

the design looks very scorn inspired iwl like it gives that like hemo-tech vibe

[@un-factory]

Everything from 3D printers to processing is amazing.😊😊😊

[@bluewinterwolf]

That looks awesome, you could probably still use those straps and add belt buckles to both on 1 side and just make the fastening pin holes closer together for a better fit, compensating for the weight.

[@charlieevergreen3514]

Truly beautiful design, and your work with it really does it justice. Great job. Next mask, you can use a very hollow back, making it like a deformed sheet, for weight, but I don’t know how difficult that would be to cast. If it helps, the prototype could be made using slip casting: a method where liquid clay is poured into a plaster mold, allowed to firm up just on the lining face of the mold before dumping out all the clay that remains liquid. It leaves a very thin shell, with all the detail on the outside, and an inside that seems like an inch of snow on the lawn. It’s similar to your ceramic mold, but on the inside instead of the outside, and done in one pour instead of multiple dips.

[@Myself55]

Looks like a few inspirations from Scorned that one video game…. Very cool

[@kentieber7309]

it was nice seeing you instead of just hearing your voice. great video and cool project

[@endless130ify]

Been watching your videos for a while now. It’s nice to see you in the video explaining. Keep up the great work

[@christopherhurray6115]

Wow, a gorgeous piece of art! Reminds me of the work of H. R. Giger.

[@allenstroud4236]

Wow! Thank you for sharing. I learned many things just by watching. Hopefully I can get set up to learn hands on someday.

[@anthonyrigley4402]

Nice idea for the hand gard when poring

[@apeschwartz]

Loved seeing you in the video

[@UKGtrotter2k]

Surprised Adam Savage hasn't had you on tested yet, Amazing work.

[@popcornboi1059]

You should make one that goes with a respirator mask

[@williamlanphar630]

Beautiful detail.

[@theawesomer]

Awesome display piece, even if it's not a practical mask.

[@frikkiesmit327]

Stop it!!! Just stop it!! Noo dont stop. You doing flippen nice!!! Real pro man. Now i remeber why i subbed.

[@AnonOmis1000]

This would be great for a Scorpion cosplay

[@zaxthedestroyer675]

This makes me think of samurai masks. While it is heavy if you created a helmet themed around this mask, you could maybe create some form of hook that attaches to the helmet

[@MeltAbilities]

‼️BadAss‼️ I ❤️ both your and Zane’s work 🤩

[@bostitchrider2026]

Wow, very impressive.

[@grifftech]

Zane does amazing 3D models!!

[@Blacksheepmylegacy]

Just a thought, if you fill a large bucket with sand, then pump air in from the bottom, So the sand is Bubbling, it would make coating the mouldings much easier and give an even coat of sand. Great Video

[@tattooeddragon]

I have this very mask! ( the plastic version ) It was my staple when covid was a thing 😊

[@andymuzzo8568]

Looks awesome

[@Constantsorrow512]

Awesome work

[@kznsq77]

Great work! You should make also a helmet and attach it to this mask.

[@emeltea33]

Super cool!

[@SteveJaeger]

That would make a great halloween mask!

[@barthanes1]

That thing is wild. Get the artist to make a matching helmet, then just hang it from the helmet.

[@Jerimahsts]

That turned out amazing!!!

[@bryrusmi4001]

Suggestion: get either black or red leather in a thin strip. Attach it to the bridge of the nose. And have it go over the crown of your head and glue it to to the top two pieces of your existing straps. It's a slight modification from the original design intent, but it would make it workable and distribute the load.🎭

[@darrinplank]

Looks great

[@00Discourse00]

Y'kno' what? Add a Kabuto helm with horns to provide support. I think that would be a fantastic way to expand your repertoire of skills, and ensure that this piece doesn't just sit on a shelf.

[@CharlieMetcalf]

That is VERY cool

[@lundgrenbronzestudios]

It would be interesting to see how thin you could make it. The thinner I go the harder it is to fill the entire area before the metal freezes. Especially with a lot of surface area.

[@charlesdebarber2997]

Leather working enthusiast here. You're not far from what you need here. You need veggie tan straps with fabric leather glued on the interior to make it comfortable. One strap needs to be along the lower crown of your head. Regardless, the weight is going to give you a neck ache. However, a better harness will make it work.

[@XXCoder]

You probably could use thick foam pads to space mask away from your face so you can tighten it to hold better on face.

[@peninsulahomerenovations9680]

wow looks cool

[@Vibraza]

Amazing!

[@JordanSpaz]

This would make a sick Dying Light 2 mask!

[@joepearson9704]

ALong with the leather straps you have, you should try an overhead strap from the ring holes on each side.

[@MichelAlexisBucio]

Great work! , you got a new subscriber :)

[@je-fq7ve]

You need a plaster cast of your face to go between you and the mask. It is not to hard to do. Use plaster bandages use for a broken arm. Start by shaving, put Vaseline on your face, soak plaster bandages and place on face overlapping. You can incorporate any straps into the cast also.

[@BLURby84]

An upper piece to go with it might help hold it well and be a great project piece to make.

[@maxcactus7]

Archaeologists in 2123 "This mask dates from the pre-Aztec period in the ancient Americas! It is a meticulously crafted piece of art and the only known example of it's kind, made in the infancy of the bronze age in the Western hemisphere. Given it's unique nature and exquisite detail, collectors value this piece in the tens of millions of dollars, if not completely priceless. As such, it will be displayed as one of the crown jewels in the Smithsonian."

[@wernerpfeifer]

Grandios!

[@paulmhoward]

This is beautiful. Can the liver of sulphur at 6:26 be used with something like painters tape to patina specific portions of brass and copper?

[@CaptainSwift11]

I would guess that the cracking isn't caused by the sand itself, but more likely that the sand had more moisture in it, and by changing sand types you simply found a dryer sand

[@Arcticwhir]

so cool

[@brianwilliams4326]

You need to cast a helmet for it to attach to, it already has the hinge point 😎 and a Silicon mold off your face to glue in, excellent work though, beautiful cast.

[@cainmatters6666]

What if you took a similar concept and turned it into a shop mask? Use riveting perhaps? Overall love the work

[@thunderbasilisk1352]

Damn that looks gorgeous! Also would a couple of adjustable buckles not work? It doesnt have to be pretty just stable enough to be able to pose without holding it.

[@Diazjake]

That’s sick! The next one should have a hinged jaw! 👺

[@haighs9900]

this is so cool! have you tried that method where you coat the print in carbon then electrode metal on to it? that would make it lighter

[@CreaSonMusik]

Hello, I just finished watching all your videos on the subject of foundry. I also aspire to get into this practice. I am looking for a simpler method for making molds, often made with red sand. I noticed that your sand + wallbord joint compound + cement floor, gives excellent results, which is of particular interest to me. Personally. Do you sell your creations? I would like an aluminum or bronze model. In any case, I would like to congratulate you on your remarkable work.

[@SkellybonerZ]

Very cool! Have you ever thought about releasing a second video of every project that was just the entire sand blasting? I know people love power washing videos and I have to say the little taste we get of the sand blasting is really satisfying.

[@insaneGeOFF]

Could you put a buckle on the ends of the leather on one side and holes on the other side and make it a belt style strap? That should hold better than tying it.

[@stevekorup7366]

Cool Project, hey on making something to help you wear the mask on a future project, have you thought about printing in some small "loop bars" that you could affix some straps to help you wear the mask Just an idea.

[@DragonAtelier]

As I am thinkig - for a bronze mask - it is too heavy to wear - even just for CosPlay of some sort. Either way - how much does it weight?

[@gloriouslumi]

Three pounds, he said. He reduced the thickness of the model considerably, but even that wasn't enough. Keep in mind that gold is twice as dense as bronze, so it can't be that unreasonable. Aluminum would be a much lighter alternative, or even Aluminum Bronze (approx 68% vs 6% density reduction, respectively). As long as it's secured properly, it shouldn't be too bad. Look at industrial respirator masks for ideas of how to hand things from your face lol

[@DragonAtelier]

@@gloriouslumi thnx for the info bout the weight. Regarding the metal choice - it was not needed - I am a metal caster myself 😉😁

[@henuel906]

Hello, can yuu use the ceramic shell to cast an very detailed bronze sword/Dagger i'm not fan at all of sand casting?? Your videos are very nice! Thx for all the good work.

[@andreseite5317]

imagine a helmet in this style :)

[@geuis]

Lovely. Easily my favorite since you did those similar style statues a couple years ago. Have you looked into doing resin printing to get finer detail and no layer lines? I've seen a few other folks on KZbin doing it, mainly for jewelry type stuff. I have no personal experience with this product, but there's "Siraya Tech Cast - Castable resin" that other folks have used.

[@WhiskeySmitty]

For this particular piece, might collab with the designer to make a helm piece that this piece can lock into. Between you and the other, I could see a full skull piece that would be pretty awesome. Hit up Prince Armory for the leather work, dude is insane with leather

[@ggbullion]

Very cool. 1st of all-- subbed. You are great, dude. Even if it didn't turn out EXACTLY as you intended, your stuff shows great craftsmanship. Thanks for giving me a motivation boost to melt & pour some silver as soon as feasible. ❤ You are making some really cool stuff, I know you're likely a bit busy to respond but I'm curious how you got into the method which you use. I, for the most part, pour into shaoes with high-density graphite molds w/ insulated propane furnace. (I'm also kinda broke, but would love to get into more of the kind of stuff you are doing some day.) How did you get into that style of pouring/metalworking? Anyways, we Smithys are total Chads 😉 Respect from Detroit. 😎🇺🇸😎

[@SomberEthics]

Hey, I don't want to tell you anything misleading, but wouldn't it be better to give the mold a better path to push air out? Like tilting it at a 45 degree angle, and also having it completely submerged in hot sand? The hot sand would cool from the top, leaving the bottom hotter than the top and preserving the details while also pushing out any imperfections of the pour.

[@manuel_13]

If you are going to do it again, you could try it in aluminium, it is much more light Weight. Pd. Sorry my english

[@ardemis_9557]

what you should have done is a metal hinge system two hinges that would go around your head and then lock it back your head so it stays put of course it would be a pain in the ass to measure it