Turn Styrofoam cups into METAL - Experimental metal Casting - Lost foam casting

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In this video I experiment with lost foam casting by attempting to turn Styrofoam cups into metal. I used drywall joint compound to coat the Styrofoam and allowed it to dry before dissolving the foam with acetone and then burying the cups in sand. This can be a great way to preserve the detail on foam objects.
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29 сен 2024

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Комментарии : 343

@robinson-foundry 3 месяца назад

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!

@ryank8113 2 года назад

This is a really cool idea and my first thought would be to doublestack the cups. Twice the wall thickness and you could keep the styrofoam texture.

@THESLlCK 2 года назад

lean cup

@MrJeepmarine Год назад

Good Idea, I was thinking that he might do that.

@Stroke-it-2Handed 2 года назад

Your level of patience is second to none. Use a propane torch to burn the styrofoam out of the molds, the foam will be gone and the molds will be heated.

@boelwerkr 2 года назад

To cast really thin things in aluminum with the lost form method, you have to heat up the mold. I heat up the mold to burn out the Styrofoam, then pour in the aluminum into the hot mold. With enough head to get the pressure high enough i can cast parts thinner than 1mm. To burn out the mold i put the mold into sand in a metal container, and then heat up everything in a furnace. The the Sand will hold the heat for quite a while. This really helps to get the liquid metal to every part of a thin walled mold. As a mold compound i use clay slurry with soap, sand and rock wool to build up thick and stable shell around the object.

@jonanderson5137 Год назад

Might sound weird, but Id like to see that process.

@westcoaststacker569 2 года назад

Awesome job and demonstration. Now I need a Circle K Polar Pop cup, the foam ones degrade quickly when reused.

@NSResponder Год назад

In industrial lost-foam casting, it's common to coat the foam with refractory plaster and sand in many layers, and then to burn the foam out in an oven before casting.

@DaaGoddy 2 года назад

Try some Ventil tubes. Like smaller versions of your feeder tube. Makes the acetone part easier and it casts much better

@Wrighmachining 2 года назад

Your a geniouse !!!!! Im trying some of these technics to improve my lost foam casting . Thank you !!

@bbrachman Год назад

I have seen others create the mold with some kind of water soluble plaster. Then heat (in a kiln) the mold to burn off the styrofoam so you have a completely empty mold.

@bryanpesce1 2 года назад

A vent tube or 2 may also help with the gassing issue as well as preheating and burning off the residue before hand.

@lyledavis819 2 года назад

I was thinking the pewter cups would be better with a mirror finish, but I actually like that they took on the texture of the Styrofoam cups.

@SeanBZA 2 года назад

Paint the cups with some white PVA paint first, to get a layer to interface with the drywall compound. Also try diluting it further for the first coat, and using a paint brush to do a few coats first, before the more thicker coats, and for glueing the sprue on take styrene and dissolve in acetone till saturated, and use a drop of that on the sprue, then touch the cup to there, no glue residue. Acetone will have to be left in for a day or so, but cure the compound in an oven at low heat first, around 120C, so as to try to melt most of the styrene out first, holding so it is sprue down in some of the sand, so the melted plastic can flow mostly out.

@lowellhouser7731 2 года назад

Having done this a few times now - thinner is not a good idea with lost foam. It's a great method for thick blocky things, and in those cases you don't need to melt out the foam because pouring temperature aluminum burns through it just fine as long as your maintain a constant pour with proper gating.

@efotube4679 2 года назад

You can get perfect casting with aluminium too, you have to bake the moulds in an oven to burn out all the styro residue, and cast the metal when the molds are still hot.

@ktlivingherway516 2 года назад

Yeah I learned that trick about styrofoam when I was trying to spray paint some once and it just started melting. Maybe try again with different kinds of foams? Like you know couch foam and things like that you could carve

@guillermorobles6381 2 года назад

I dont know what it is but you are incredible

@preoco8241 2 года назад

preheat the mold will help the aluminum casting.

@talgirrafe 2 года назад

Normal People: When i see Styrofoam cups they are just Styrofoam cups Robinson Foundry: When I look at Styrofoam cups i wonder if they can be turned into metal Me: when I see Styrofoam cups i see food

@SandCrabNews 2 года назад

Gasoline is a solvent of Styrofoam. Would Plaster of Paris be a better mold, eliminating the drywall joint compound? Then you might try Copper, Brass, Bronze, Silver.

@PacoOtis 2 года назад

Dude! Bravo! We owe you a beer!

@jjcc8379 2 года назад

I feel like there should be sprues from the rim for ventilation purposes. If when disolving the cup or pouring air gets trapped in the thin walls ... it will bubble or get trapped there.

@theatomproject007 2 года назад

Welcome to Saturn circa 1991 when the first Lost foam casting engine assembly was produced by GM and went on to be used across various GM lines to this day.

@robinson-foundry 2 года назад

I didn't know that! Very interesting.

@ztwilkerson 2 года назад

You could make a design in the styrofoam and transfer it easily to the casting, like when people use their thumbnail to put in the initials…

@Loganvbills 2 года назад

Turn them into bells? They sound nice

@alanjagroop1282 Год назад

It does have a easier way. To put in sand and cast without adding those extra mixtures.

@Convolutedtubules 2 года назад

I think the entire mould needs to be left in acetone for it to dissolve. I would love to see this attempted again, with some better equipment and other metals like copper.

@NedFlanders612 2 года назад

How about a Dixie cup! You gotta make sure it's red with a white rim. Come on, let's see your painting skills 😀 Happy 4th of July, btw. You could make 12, then play Beer pong with the Mrs. and close friends

@gerardj.lesperanceiii1238 2 года назад

just like to know could you use them to drink hot or cold beverages from them or do you have to use a different kind of metal

@chadwickhjones Год назад

How do you know the vermiculite is not ACM asbestos containing?

@spork861 Год назад

So I've been thinking, all these youtubers who show off lost foam or lost PLA method casting, and they use various materials for encasing the material, like either some type of special plaster or that expensive as hell yellow ceramic stuff, and then spend a week to add thin layers over and over, that makes me wonder the whole time like what if you just use straight up pure cement, like add a layer of pure portland cement as and lather that on so it retains the details, then encase that in a thick thick layer of mixed concrete (so portland cement, sand, aggregate). Like, wouldn't that be strong enough to withstand heat? Sure it might take a while to dry out completely, so timewise it might still suck like the other methods, but it might be an inexpensive sturdy option. Has anyone tried that? Using cement and concrete instead of ceramic slurry or plaster?

@ronbrandich4196 2 года назад

Neat!!!

@mittens4859 2 года назад

I can't drink from either a Styrofoam cup or a metal one :D It would be cool if you could paint the metal one white with food grade paint, make it look like Styrofoam again

@j4ck3t 2 года назад

shouldn't you have made a overflow channel? that also acts as a channel where the gasses escape? I Believe that is common when using a lost casting method using highly flammable materials.

@asmrwiz-m4e Год назад

Can i use 3d printed object instead of styrofoam

@micahpickering2068 2 года назад

Have you ever tried using sheetrock as a mold?

@eprofessio 2 года назад

The aluminum would work perfect if it was a little hotter and the fill riser were taller.

@yumisuremaki2748 Год назад

quention is can you drink out of them

@MikeCore 2 года назад

notice a trend of you getting more views with every thumbnail that uses the name on the left and a dark gray/black backdrop, just a note

@unclesmrgol 2 года назад

Strange. No chocolate frosting on the aluminum ingots.

@RyeOnHam 2 года назад

Insulation not up to par, I'd guess.

@redneckhippiefreak 2 года назад

Just need to preheat those molds so it drives the rest of the rest of the Styrofoam out and prepare the plasterer for the heat extremes. . Mix in some sodium silicate with plaster of Paris for your investment media. , , It will help refract the heat a little better as well as help those molds hold up and probably leave a nicer finish on the aluminum.

@Spencer19165 2 года назад

Well done came out great. What was the stuff u filled up the cup 2:35?

@anzaca1 2 года назад

He tells you. Go to 2:32, and listen to what he says.

@Spencer19165 2 года назад

@@anzaca1 yes I know I am trying to figure wtf is in it

@MangoMike316 2 года назад

👍👍👍

@pepsiman1488 2 года назад

Imagine drinking lean out of this

@TimmyGC 2 месяца назад

This only allows 340 or 1080 premium... Ok RU-vid.

@robiedriscoll6280 2 года назад

You could try preheating the molds, it give you a little longer for the metal to flow into the gaps

@Razza2250 2 года назад

kilning them would get rid of any residual styrofoam/acetone slurry as well

@anzaca1 2 года назад

This is something companies actually do.

@stevebray71 2 года назад

I was actually thinking that he could do as u mentioned. This would help to take out the poli styrene from the mould but again you would possibly need to be careful about the mould cracking in the heat cycle but it could help to stop the water from the joint compound from boiling so quickly with the water then also causing problems with the mould filling up easily because of the small thickness of the cups same thing really as lost pla if you don't get rid of the pla you have a lot of issues with the mould filling even

@joejoejoejoejoejoe4391 2 года назад

It does look like cold lap, something that I have experience of when the metal is too cold when poured, however if the metal is too hot, it's so runny it runs into the sand an you get a sandy casting ( like a casting, but with a metal/sand skin )- not good when zirconia sand is used, it blunts carbide tools like you wouldn't believe.

@allangibson2408 2 года назад

Acetone dissolves styrofoam - it doesn’t remove it, it just leaves a varnish of polystyrene behind. Heating the molds to ignition temperature of the polystyrene might help because otherwise you are fighting the combustion gases from burning styrene in trying to get metal into the mold.

@zumbazumba1 2 года назад

And there is no gas vent so all the gas is trying to go up,from which you pour metal .And thats why it had so much porosity . Pouring basin and sprue are a joke.

@sealpiercing8476 2 года назад

Why not burn out as much foam as possible after clearing most of it with acetone, as in lost PLA casting? As you point out the thin walls are already pushing it so no need to add foam residue as a second complication.

@TravisFabel 2 года назад

This is what I was going to suggest. When you melted the styrofoam, you created solid plastic in areas. You could see that in the casting attempt. If you were to burn out all of the styrofoam, not only would it all vaporize as a gas, but it would preheat the mold for when you pour into it.

@KrazyMitchAdventures 2 года назад

The problem is, he used Drywall Compound, which is gypsum dust mixed with water. It doesn't do well in extreme heat, so burning it or heating it in a oven, would reduce it back to gypsum

@bishopcorva 2 года назад

I was likewise thinking that heating the moulds to burn out the foam would work well, even more so if you used plaster built in layers very thin mix at first then gradually thicker coats in layers. Add in increasing amounts of silica sand then when estimated about three to five millimeters thick. Just heat in the casting furnace to burn em out. Then do not let them cool before the pour. Pour the aluminum while the moulds are still glowing hot. The heat of the moulds will help the metal to stay flowable until the temperature drops to freeze it in shape. After that it's just dunk in water to cool even more and get the moulds to crack from the temp swing shock.

@bishopcorva 2 года назад

@@KrazyMitchAdventures hence why I said plaster, as shortened for plaster of Paris. Gypsum while it does contain some likeness to plaster of Paris, it is not the same as. I know how to cast using plaster embedded with silica dust and sand at very high temps, that when quenched the plaster crumbles into a slurry in the quench water. It's a fantastically interesting process and very dangerous to do if you are not wearing protection, since the risk of splash burns is quite high when the just off incandescent mould and metal hits even rolling boil quench water there is quite a bit of stream and lots of popping taking place. So if you do it, be extremely careful and don't stand right on the quench. Long grippers are a very handy tool for that kind of stuff.

@sealpiercing8476 2 года назад

@@KrazyMitchAdventures That's true. He would need to use the suspendaslurry stuff.

@Slide100 2 года назад

What about building a couple of small diameter vents off the rim back up to the top? That would vent the air, you probably wouldn’t get the bubbling, either. Might be worth a try 🤷‍♂️

@joejoejoejoejoejoe4391 2 года назад

A bottom fed casting would be even better, allowing the gases to exit through the riser instead of flowing against the flow of metal. On some small castings, spikes are poked through the sand to touch the pattern to give a path for gasses to vent out, and the resulting metal that enters the vent can be easily snapped off.

@keithyinger3326 2 года назад

@@joejoejoejoejoejoe4391 I cast bronze coins and thats the method. I use a flat two-part sand mold. Metal goes in one edge of the coin, and I have 2 small air vents at 1/3 and 2/3 position going up. That way, the metal can flow in and push any gases up and out the vents as it flows. It also helps when you're casting things like animals, flat, that have four legs and a tail. Put an air vent at each extremity or it won't fill completely. Those extra small "sprues" are easy enough to cut off.

@aserta 2 года назад

I think the problem with the first (shown on camera) casting of the cups was the fact that you stopped. You should continue even with there's a flash. It's normal to see stuff like that when you burn lost casting material. The concept worked, incredibly well.

@demitv001 2 года назад

@Robinson Foundry could these cups be then used as a mold to do loss casting with aluminium and other high temperature metals?

@anzaca1 2 года назад

Probably. The sand etc is what handles most of the heat.

@presidentjoethudbrandon7074 2 года назад

Maybe if you preheated the mold to burn out the remaining Styrofoam you could avoid off gassing and fire. Acetone will dissolve the Styrofoam but not remove it. It just turns into slime that takes up far less space

@milolc 2 года назад

Couldn't you preheat the mold? You would probably need to do a different style mold, but if it is already hot when the metal is poured there would be plenty of time for the metal to flow into all the little cracks and crevasses before the whole thing slowly cooled.

@slimsantilli4476 2 года назад

Cool! My family has an aluminum foundry. One day a guy up the street brought in a display figure of the Pillsbury dough boy. It was made from styrofoam. We covered it with nobake sand and cast it. He put the casting in his front flowerbed. You did a good job gating the cups. One trick that helps is to run a narrow hole next to the inlet. A "riser" hole to let gas out. A 3/16 rod hole is all you need.

@rachelg552353 2 года назад

Interesting experiment. Styrofoam teddy bear next!

@haph2087 2 года назад

Preheat the cast. *Preheat the cast.* **PREHEAT THE CAST!!** I wonder if that would help. But it’s what my brain screams when the metal cools too quickly.

@thomasthecrunkengine3512 2 года назад

I really hope this hasn’t deterred you from trying this with higher temperature metals. It would be nice to see an aluminum, or even a bronze styrofoam cup!

@FWPrecords 2 года назад

The experiment left you with some cool looking cups! I think they turned out good. Never thought I would see a nice metal Styrofoam

@Danielhofjr 2 года назад

If this is an in-between video, I'm not sure I'm properly prepared for what comes next. 🙏

@Polocruz81 2 года назад

Did he really need a knife to cut that he could have just snapped at styrofoam 😐😐😐😐😐

@Thee_Sinner 2 года назад

What about baking the molds before casting to burn out the remaining foam?

@shannahmiller 2 года назад

This was really interesting. The pewter cups look really good.

@jayhawkrulz3375 2 года назад

Jesus loves you all and have a great day also remember to not say the Lord's name in vein and to say your blessings before you eat.

@notreallyme425 2 года назад

Technically, those cups are just “foam’ cups. Styrofoam is a trademark and is extruded, while the cups are expanded polystyrene.

@zumbazumba1 2 года назад

Expanded polystyrene is worse for casting ,extruded leaves much better finish . Both can be used thou.

@bashkillszombies Месяц назад

I haven't seen a styrofoam cup since the 1980's, why are you guys still using those horrible things? Stop! It ain't worth it!

@frankierzucekjr 2 года назад

I gotta say, the packing peanuts look so freakin cool. The cups came out cool too. Like mini trash cans lol

@general5104 2 года назад

EXCELLENT EXPERIMENT !!! In my younger days as a Die-Maker, the shop I worked at, made a pinned together Aluminum mold to inject red wax into. Then open, clam-shell like, and the wax part was removed and close the mold and do it all over again. They would then, coat those with potters slurry and add fine sand, and allow to dry, and layer it many times. Then cut a sprew hole and Fire the mold into porcelain, and pour out the wax. Then pour Stainless Steel in the sprew hole and allow to cool and drop it in a shaker bin with metal BB's and a Stainless Steel part emerges. Cut and dress where the sprew was and have a finished part in a very quick time. It turns out that those were Turrent mounts for Huey Machine-Guns. They were intricate parts. & made from Stainless Steel, it would have been hard to make those. That's kind-of what you're doing here with FOAM instead of "Lost Wax"

@THX..1138 2 года назад

I remember reading about aluminum casting temperatures, as little as 50 or 100 degrees Celsius can make a big difference in how the metal flows....Casting something so thin the you may have needed the aluminum to be a little hotter and or needed to preheat the mold so the metal stayed hotter longer.

@smokingfish668 2 года назад

0:30 ah yes metal peanut, now even more tasty

@Croatilillious 2 года назад

The drywall joint compound looks really tasty ngl

@MilesProwerTailsFox 2 года назад

those are 99% air so pretty easy to cast em

@catgynt9148 2 года назад

What a great experiment and an interesting end result. Are there any thicker styles of styrofoam cups that are available? Alternatively, can you cast two cups together? Perhaps trimming the top of the inner cup to appear to be a single cup with a smaller interior. Wishing you a blessed week, gentle weather and restful evenings. Peace brother

@frankdoss6313 2 года назад

JOINT COMPOUND!!! I should have thought of this! I wonder if purging acetone & styrafoam remnants with a torch would have helped.

@PalpatineMartini Год назад

2:56 forbidden Reese’s cups

@rickhalverson2252 6 месяцев назад

Drill some very small holes in the bottom of your mold. Cover your sand/ box with thin plastic. Add a secondary box below with vacuum.

@DaHaiZhu 2 года назад

Maybe suspendaslurry and burn the Styrofoam out and preheat the mold?

@kiraly_gabor 2 года назад

It was a nice save! :) In 1986 we worked with lost styrofoam technique but not with so thin pieces. But before I forget: I sent you a sponsorship offer, please check your mailbox (incl. the spam folder)!

@zumbazumba1 2 года назад

THIS IS A TUTORIAL ON HOW NOT TO DO IT ! I respect your skills but wtf was that on 1:49 ? That's not how basin and sprue should look like ! Its a joke ! No wonder you got so much porosity . There are no gas vents on the mold ,you didnt burned out styrofoam after acetone dip ,so it burned out and made gas -gas that wanted to come out trough the sprue ,but you are pouring metal trough that joke so the gas went down into casting . I recommend you read trough C. W.Ammen book "Complete Handbook of sand casting" . It is a interesting read and he goes in detail . Same rules apply for lost foam -investment casting as in sand casting . It just needs gas vents as well since it is a shell that doesnt have porosity of the sand that will let gas pas trough. You will get much better results .

@TheMindOfBrick 2 года назад

Styrofoam isn’t used in the manufacture of cups. Styrofoam is a brand name for a formulation of polystyrene specific to wall insulation. I believe the rights belong to DuPont. Not the same argument as “Bandaid/Adhesive Bandage” because they aren’t apples to apples. Trivia not trollin…

@sergeantcraphead 2 года назад

Bro that's awesome 😎

@wendyrobertson3899 Год назад

Those would make awesome bells on a wind chime. I've used pewter cups, decorative baby cups and several different decorative vases to make bell wind chimes and my customers adored the muted ring of the "bells". Why not try hand crafting squiggles of flat metal to make pewter wind chimes. Since I'm no longer able to do the physical part of carrying the crucible I would seriously love to get a few extra long, medium and short length pieces that I can make into pretty awesome chimes. Would you be interested in doing something like that for purchase? Let me know and well talk about it?

@alumcreator 11 месяцев назад

You never mentioned pouring temperature, although you mention melting point. The thinner the wall the more over melting point you need to pour it. If I were pouring something that thin the metal would have been glowing orange. Funny how I didn’t notice any comments about temperature either, it’s one of the most important factors in getting good results.

@incandescentfennec6916 2 года назад

Here's a tip, if you plan on drinking out of those cups (for whatever reason) avoid putting acidic drinks in them. Especially tomato juice. The acids can react with the metal and form toxic compounds. Could be a clever way of poisoning someone...

@haydenc2742 Год назад

wait...is that drywall compound like suspend-a-slurry?? Could it be used by coating with the silica sand and making a mold for other things?? Also I am wondering if it could be heated like the suspend-a-slurry and silica sand in the kiln...

@unstablenester941 10 месяцев назад

Great video. I'm playing with casting and I will be trying something like this soon. Would vents for escaping gasses hve helped?

@dash8465 2 года назад

See the videos on how small boat propellers are cast in aluminum and stainless. Its basically a dip/coat/dip/coat buildup then kiln dried/hardened to become a ceramic of some sort… your styrofoam cup would vaporize, final clean/rinse/blow it out, then reheat (or pre-heat) to ensure its completely dry inside.

@meetthebutcher 2 года назад

I don't know that brand of mud , you can take a mixed to your liking spoon full and fling (yes fling or drop ) it on to a unfinished white paper side of a small piece of sheetrock . true lightweight "topping" not joint compound should scrape free with a putty knife w/o tarring any paper off the board. In the past "joint compound " has always had good amount of glue in it to guarantee when taping the sheetrock joints the paper tape makes an extra good bond to is the boards. If they where to move over time the seems wont crack and show through to the painted surface of interior walls in theory. So your cleaning issue could be glue and a solvent mite make short work , some companies add other things to mud to increase the chance a home owner will grab their brans . Like paint ,going as far as to claim if used for texturing ceilings one could skip painting ... Always seal new sheetrock or you will regret it in the long run . Back to it do the "messy taping apprentice leaving joint compound buggers on the new walls to dry test " ( if the paper tares you have to skim and sand every spot or it will show when painted ) and see what brand comes free with the least effort .. good toping should almost snap off with one motion/scrape. And bonus tip in a 5gal bucket when we mixed toping the pros add maybe a coke bottle sized amount of dawn dishwashing soap the liquid kind , but that ratio is to 1&1/3 boxes of mud so you would need much less , but the soap stops air bubbles from appearing in the mud when we would coat joints and butts and pull metal on the job .. You may have a use for this maybe not . Liked seeing the mud baked like that and the sound lol great stuff man!

@TheFishingExperience916 2 года назад

Im telling you that is something im going to try making out of aluminum it would be cool AF to drink out of a painted white "ALUMINUM cup" shaped like a styrofoam cup lmao

@mfsamuel 2 года назад

Because you are filling the molds from the top you don't have a path for the air to escape. You should have your sprue go all the way to the bottom and allow the metal to flow upwards, with the column of metal acting as a pressure column forcing the air up and out though a vent located at the top (where you placed your sprue).

@sangeenshahkhan 8 месяцев назад

Absolutely terrible lost foam method but you did a good job at coming up with alternative to expansive coating slurry. can you try lost wax method?

@mathbc1984 2 года назад

If you want to cast alluminium again, you need 1 more step in the process for the metal cup casting. You need to remove the reminding foam with heat in your furnace.

@merkel2750 2 месяца назад

Does anyone have a link to cheapish casting slurry or a diy recipe that works? The only stuff I can find is sold in bulk lots or is insanely expensive

@4110mahindra 2 года назад

Industrial lost foam foundries don't dissolve the foam. Foam in the mold isnt your problem. Those "molds" should be heated to around 100 f for 36 plus hours before casting and they should be thin enough to allow off gassing into the sand. Don't get yourself killed.

@JohnFourtyTwo 2 года назад

I couldn't help but think of an old Star Trek episode where they were drinking coffee on the bridge out of Styrofoam cups painted silver.😉☕

@3dagedesign 2 года назад

This is originally known as the "Lost WAX" technique. as used by artists since (at least) the ancient greeks. a wax scipture is created, then placed in sand, then molten metal is poured which melts the wax, allowing the metal to fill the void.

@TacDyne 2 года назад

No, drywall mud will not react to acetone, but it is radioactive. Sheetrock brand used to keep a warning label on the box about the radiation exposure hazard. A lot of people complained about it, saying they didn't want to use it since it was radioactive. So Sheetrock removed the warning and everyone was happy.

@ElixirofRides 2 года назад

SICK! Keep up the cool vids!

@kursor6127 2 года назад

Great idea. First attempt could work but You need to pour faster. Not from crucible but useing spoon that you'll empty in 1 seckond. But to pour so fast plaster cant be saturated with disolwed foam- to much gases.

@kursor6127 2 года назад