We recently showed you how aluminum-based 3D printing is bringing customized objects to space. For those of us that can’t afford a 3D printer but enjoy a bit of DIY craftsmanship, here’s the next best thing. The self-proclaimed King Of Random recently put together a how-to video offering a technique that involves styrofoam, aluminum cans, and sand. The result is something pretty close to a 3D printed object, though the process is a little more dangerous than uploading to a 3D printer. From Gizmodo:
If you’re looking for a fun, high-risk weekend project, look no further: Grant Thompson, the self-styled “King of Random”, has decided to shared his method for transforming styrofoam into metal. (Spoiler: don’t try this one around your kids.)
To start, you’ll need to cut a model of your soon-t0-be metal creation out of foam. Thompson suggests using foam board from the dollar store, but foam housing insulation or craft blocks will work just as well. Once assembled, attach a thick foam riser to the top of your model, and bury it in a 5-gallon bucket filled with sand.
Next you’ll have to fire up your homemade metal foundry (if you’ve never made one before, Thompson’s got you covered). Now melt down some aluminum cans and pour the molten metal over your buried foam cast, taking care not to splash anything on yourself. The foam, Thompson explains, will vaporize instantly as liquid aluminum rushes in to take its place. Within a few minutes, your sculpture should be cool enough to remove. Do so carefully, using pliers. You can then polish up your new creation and place it prominently on display.
Click here to go to the full article, including a complete video demonstration by the King of Random. Just remember to use gloves and pliers when you try this yourself.