Aluminum face cast process

Check the gallery for step by step instructions.

WARNING: Working with molten metal can be FATAL. Exercise safety precautions at all times.

Aluminum melts at 1220 degrees F and that means third degree burns if you are careless enough to forget that.

1. 3D scan your face. This scan was done on Next Engine with Scan Studio on high resolution.

2. 3D print the face. Use proper support and carefully clean with needle nose pliers.

3. Vacuum form the results. I vacuum formed the face print with a Formech system.

4. Plaster cast. Mix some plaster of Paris with water to create a negative mold by placing the vacuum form into the liquid plaster. Allow 6 minutes to harden! After that, slowly pinch out the vacuum form and you're ready to pour hot aluminum only after you BAKE your plaster mold. Do not forget to cook your negative mold to evaporate all moisture.

5. Pour molten aluminum. Carefully pour your aluminum into your negative with a reservoir runoff for over pourin