RE: New Venture Progress!

This is the tool to cast the metal Harley emblems?From robjh22

It’s part of it.

What you’ve seen so far are digital renderings and the occasional 3D print.

The process, end to end, looks like this:

  1. Create a mechanical model of the blank part using Fusion360 CAD software.
  2. Create the design (the decorative part) using ZBrush 3D modeling software.
  3. Import the mechanical part model into ZBrush, and “fuse” it (digitally, that is) with the decorative design.
  4. Send that combined 3D model to the 3D printer to make a full size positive version of the part.
  5. Use the previously described process to make an RTV silicone “negative” mold from the 3D print.
  6. Use the negative mold to create a positive copy of the part out of wax.
  7. Attach wax sprues to the wax copy to create eventual pathways for the metal to flow.
  8. Embed the wax stuff (wax model + sprues) into “investment” (which is essentially a special high temperature plaster, mixed to pancake batter consistency) inside of a flask. Let the investment dry to a solid.
  9. Melt the wax out of the flask using low (household oven type) heat, leaving behind a negative copy of the part in the investment.
  10. Cure the flask+dewaxed investment in the above pictured kiln for approximately 24 hours, according to a special heating schedule.
  11. After the curing cycle is complete, melt a supply of metal in the “blast furnace” (technically a “foundry”).
  12. Pull the cured flask from the kiln (still at “casting temperature”…about 1000 F) and place it on a vacuum table. Activate the vacuum, so as to draw air from the mold.
  13. Pour the molten metal into the flask, filling the space left behind by the melted out wax from step 9.
  14. Let cool, bust out the investment, cut the (now metal) sprues from the parts, clean up, polish, etc. 

And just that easy, you have the most beautiful motorcycle part in the world!

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