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These Custom-Sized Wingnuts are Made By Sand Casting 3D Printed Parts

by • February 21, 2016 • No Comments

nutsThe term “sand casting” refers to precisely what it sounds like. It is a really common way of casting metal parts, via sand as the mold. This is a really talked of method of casting, with roughly 70% of all cast metals turn it intod by the sand casting system. Well, if you are into 3D printing, you can in addition sand cast via 3D printed parts for the mold. A new blog post by Frankie Flood documented, mostly in photos, the technique he utilized to manufacture his own custom-dimensionsd wingnuts based on hardware CAD files.

Flood’s experiments with sand casting are documented on his blog, and here he explains how this all came of. He credits McMaster-Carr, parts supplier to global industrial and commercial facilities, for producing their hardware CAD files on the market. This allows for individuals to 3D print them in a hurry, which is what Flood requireed when he got involved in sand casting 3D printed custom-dimensionsd wingnut parts.

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“You have to love McMaster-Carr. They’re kind adequate to post CAD files of their hardware,” Flood told Make Magazine. “This manufactures life easyr when I require a wingnut in a hurry or if they don’t have the dimensions I require. This happened this past week, so I downloaded their file, scaled the version to the dimensions I requireed, printed it out on the ZCorp 3D printing device, turn it intod a sand mold of the print, cast it in bronze, cut off the sprue, sandblasted, drilled and tapped on the lathe, polished, and and so installed it. Not really as easy as placing an order, but they didn’t have what I wanted anyway.”

IMG_1104Working with his 3D printing device and the sand casting technique, with several extra post-systeming and finishing steps, Flood was able-bodied to fulfill his own require for custom-dimensionsd parts which the company may not have been able-bodied to donate anyway.

Later, Flood’s photo gallery expanded when he requireed additional custom-dimensionsd wingnuts. In casting, flasks are the molds utilized, and sand is utilized within them to hold the shape which becomes the bronze metal part. Flood describes in additional more detail how he managed to do this via a few hometurn it intod flasks he turn it intod on his South Bend lathe. (A lathe is a machine which rotates a workpiece to turn it into an object with symmetry, which is how you want your flasks to be here: symmetrical.) Here he explains this system further:

wing2“My flask just has a tiny lip which fits within the other half so they fit together nicely. I have turn it intod an indexing mark as well so I can manufacture certain the two halves are aligned when I take my pattern out and put the flasks back together. These may be created out of approximately anything. I’m via delft clay/sand of Rio Grande. You may in addition use Petrobond and a few individuals manufacture this themselves. My just advice is manufacture certain to separate the charred sand of the great sand after you pull your finished cast piece out of the mold. Throw the charred stuff out as it can ruin your sand if you mix it in with the great sand.”

Got it yet? If you are brand new to the system, this is a lot to take in. But with Flood’s descriptions and extensive photo documentation of his own system, now we understand additional of how to sand cast via 3D printed parts. This is significant, especially when you may already understand which you can not be able-bodied to order a correct part dimensions anyway, requiring much technology and a 3D printing device — of course! Discuss in the Sand Casting 3D Printed Parts forum over at 3DPB.com.