Cane Handle

thingiverse

I created a replacement cane with a 22mm diameter shaft for my personal use. I designed this custom piece to match my existing cane head, and it was printed in PLA to be later cast in bronze. Here are the steps I took: For those of you who want to learn more about lost PLA casting, let me tell you that it works very similarly to lost wax. First, print your object, then apply a layer of wax to its surface using sprues. Pour a thin investment layer over the sprued item and let it cure completely. Then, carefully burn out the wax and PLA from inside the investment material, leaving a cavity in the shape of the final piece. After removing the investment, pour molten metal into the mould. In this case, I was working with a larger-than-usual bronze casting (about one pound troy), so I decided to let it cool slowly instead of quickly quenching it. This helps avoid fractures from forming in the casting material. The images that appear dark are actual photos of the piece taken immediately after removing it from its mould. As I began removing the sprues, I used a grinder to soften any sharp edges left behind by the burn-out process. Some parts of the PLA didn't completely disintegrate and there were some gaps which I filled in with hammer-driven bronze and soldered securely into place. Once cleaned and polished, I coated my new cane head with paint. Using small, deliberate strokes of a scratch tool, I textured the paint for added realism. Finally, after two hours had passed and I deemed the etching deep enough, I carefully removed the piece from its ferric chloride bath and completed it by giving it a final polish using sandblasting before the finishing touches.