I have had some success casting various objects from aluminium and now I am trying to cast a flywheel using the “lost foam” technique.
Showing the router with 6mm cutter which includes a top bearing. Below is a 3d printed pattern, from telford3dprinting.com, attached to a 10mm block of expanded polystyrene. The idea is the ball race bearing follows the pattern and cuts out the ‘foam’ object. The block was made from 3 layers of ceiling tiles bonded together.
The cutter makes quite a good job but there are a few holes from the ceiling tile pattern which are filled with hot wax.
Left showing lost foam patterns buried in sand, right Feeders and Risers before and after removal.
Showing my backyard casting setup. The Feeders and Risers are made from Plaster of Paris an idea from the “vegoilguy”
