3D prints to SOLID

thingiverse

Making strong parts or cast parts should be simple in 2019, right? Well, just do it then. I need a CNC machine to make aluminum parts, but the prices for good machines are intimidating. I decided to make my own instead. The Z axis has to hold a small router from Home Depot, and that part needs to be strong enough to support it. So I 3D printed my own part and turned it into a solid. How easy is that? Design your part, print it fast with .3mm layer height, no support, and just a Brim. Drim is also optional, but it gives you another layer of containment from the liquid Alumilite or two-part Resin Chemical, available in many stores (Walmart, Joann's, Hobby Lobby, or online). Once your part is designed, export it as STL and open the Cura application (if that's what you use). To print the part quickly and with fewer gaps, set your settings to .3 MM layer height, .08 MM shell, .12 MM bottom, 0% infill. See pictures for all my settings. At print time, try to catch the machine before it prints the top. Stop the printing at this point. If it finishes, just make two 1/2" holes to pour in the epoxy. Make a small batch of epoxy in a cup (follow the instructions on the product packaging). The first batch should be enough to cover the bottom of your part, then make more as needed, making small batches to continue filling the part. Don't try to fill it all at once; you might end up with a mess. Also, slow down in sections where the printer made errors and required support. It will leak, but don't worry about that - you'll be able to clean the part very nicely once you're done. Once done, clean off the excess with a sharp tool and scratch it off. Then sand the top smooth. You can spray paint or leave it as is; you're done! I welcome any comments or ways of improving this method of casting. Thanks!