Foam to Aluminum

Process is called " lost foam casting" ( at least it was when I was in college. It is actually how the engine blocks on Saturn cars were made.
 
The "lost wax" and greensand casting processes make for much finer detail, but that takes a few more steps. Have been involved with this work using aluminum and bronze for a while. 6 generations of blacksmiths and metal workers in the family... expensive to get set-up, and this guy makes casting sound a lot easier than it is at time, but it's a lot of fun.
 
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