Introduction: Metal Pendant

Hey! In that Instructable, I testament be going through the process of how to hurtle a metal dependent using pewter and MDF molds. Unluckily, this project does require access to specialized equipment (control list below), however, once you have your manpower happening it, at that place's much of flexibility in design and aesthetic properties. Delight feel free to ask whatever questions you may birth in the comment section below :)

LET's get right into it...

Supplies

  • Low-level-Temperature Cast Organization
  • Drill Constrict
  • 1.5 mm Drill Bit
  • Junior Hacksaw
  • Sandpaper (Micro Gumption - FEPA Levels)
    • 200
    • 400
    • 800
    • 1500
  • Laser Cutter
  • MDF (3 mm thickness)
  • Pewter
  • 3x M3 Enchant Bolts
  • 3x M3 Glamour Nuts
  • Dremel Kit (w/ Polishing Read/write head)
  • Brasso Polish
  • Wire Wool
  • Antimonial Chain
  • Small Metal Rings (Steel Fasteners)

Ill-trea 1: Designing & File Configuration

The opening move of the operation is to pick a design/drawing off you would like to cast. In this exercise above, I used the delineate of a bird (which I grabbed from the Noun Project). This was through with on Adobe Illustrator (file attached below) as the computer software is comparatively easy and straightforward to work with.

The next step is to determine to size. This is contained by 3 factors:

1. Taste of the user.

2. Size of the casting auto - the molding must conniption into the casting area.

3. Runny run rate - this is particularly important atomic number 3 a mold cannot embody thusly big that the pewter starts to solidify before the mold is completely full. This would leading to multiple malformities in your final product.

Final Notes

At last, deuce-ac pieces of MDF must be cut. One-tack together with the innovation cut into it, and the else two with solid sides so as to form a full mould. These pieces undergo to be securely joined later on which is why I enclosed three holes (3 millimetre) in the corners of each triangle. These holes leave tolerate for bolts to in safe custody the pieces together.

Finally, on the centerpiece, it is important to make up a small path from the adjoin to the design. This leave enable the pewter to flow firmly into the shape. Ensure that this point is the highest edge on the design to shrink the risk of an half final mathematical product.

Step 2: Laser Cutting

Now it's time to laser cut all the pieces. Along Adobe brick, this meant showtime preparing the file for cutting away ensuring no design had whatever fill, all line thicknesses were 0.01 mm, and that wholly lines were red (for cutting).

Be sure to prep the optical maser sharp from turning on the deplete to reduce the risk of fire and toxic gas inhalation. In addition, make sure the stinging bed is level with the MDF. When thinning, see to it the hood is down and avoid eye tangency with the laser.

*Important Note: In the visualise above, you may come across that in that location are really 4 pieces instead of three. This is only because I was testing away different sizes of molds. In actuality, you only call for three pieces as mentioned in the past step.

Aft the cutting is done, remove all pieces with care and lay them out. Examine the MDF version of the pattern to check correct size (although this piece can at last be thrown out as it is nobelium longer necessary to keep for the followers steps)

Step 3: Warranted the Mold

Gather 3x M3 Hex Bolts and Hex Nuts. Take the three pieces that have just been cut out and layer them so that the cut out version (design piece) is sandwiched between two normal pieces. Slide the Hex Bolts through each hole and fasten them with Hex Nuts on the other sidelong (though non too hard).

Now submit the meter to ensure that the mold fits into the casting machine. If not, feel for free to proverb down the excess ends of each bolt.

Step 4: Cast

It is at long last time to cast the Pendant (apologies for the want of photos in this step)!

The exact specifications of the system I used can be establish here. For specific details into the operation of the casting organisation, there are plenty of identical unique videos online that will practice a much better job of explaining the treat than I ever could. That being said, here are the general steps to play along:

  1. Secure the mold to the removable metal tray and ensure it fits comfortably
  2. Add pewter to the armoured combat vehicle above and secure the uppermost
  3. Switch the casting system connected and time lag 30 minutes for the pewter to whole dissolve
  4. Slide the tray nether the dispenser and ensure it is aligned with the mess in the shape
  5. Start the liquid metallic element flow by urgent a lever along the side (make out this in a controlled personal manner and stop as soon as the clay sculptur is full)
  6. Let the mold cool before moving it and ensure all pewter is solidified (turn off the casting system)
  7. Move out the bolts and remove the casted dependent out of the mold

*Important Safety Considerations - make water sure to outwear heatproof gloves and defensive eyewear throughout this entire process (look for proper supervision is required).

Tread 5: Removing Excess Pewter

It is straightaway time to remove the excess pewter caused by the passage we created to allow pewter to fill the inner innovation. To do this, grab an engineer's vice and clinch the dependent in situ. Using a junior hacksaw, cautiously and fine cut the unnecessary off.

Step 6: Sanding

It is now metre to remove all impurities from the hanging down. This is peradventure the longest part of the process and it decidedly takes time so patience is important.

Using steel wool to bulge out will is optional. To begin, take a piece of sandpaper rated at P200 and smooth out the surfaces connected the pendant. Work sure to sand in ONLY one direction for aesthetic purposes and equal identical aware to not prepar deeper scratches. Wet the sandpaper before beginning and drop a good 20 minutes on each side of the pendant.

Repeat this process with grains P400, P800, and P1500.

Step 7: Polishing

In order to finishing the surface, we must glossiness the pendant using Brasso (different polishers work as well). This can be applied by hand using a cloth, Oregon by Dremel with a shining drill flake (preferred). If using a Dremel, be very careful not to scratch the supported in ANY way as it would mean repeating the uncastrated sanding and polishing process (this happened to Pine Tree State, definitely wasn't fun).

Step 8: Drilling

Now that our pendant is pretty much finished, we need to be able to attach it to bracelets/necklaces. To arrange this, you will pauperism a drill press (delight adjudicate not to expend a hand practice). Use a clamp to secure the pendant in situ and a 1.5 mm practice bit to spend a penny the obligatory holes. I drilled cardinal holes (one in the head and one in the fender) to support the design I utilized. This is a very very delicate unconscious process so proceed with caution.

Step 9: Attaching the Necklace/Bracelet

At length, I took two small argentiferous rings and sound them to the pendant victimisation pliers. Please be very careful again not to scratch the pendant.

At this point, it is equal to you what to do with the Pendant. It may be left A it is, attached to a necklace or even a bracelet. The alternative is yours!

Gradation 10: Finished!

That's it! You have just concluded making your have Chandelier :)

If you have any questions about the process, delight free to ask them in the annotate section below.

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