
One of my goals, while working at DAAP, has been to help students achieve higher quality in their products than the technologies of laser machining and 3D printing are capable of on their own. This project, carried out at the DAAP RPC, began as a question from a student in my first year class. The student was designing a chess set with pieces that were metal and had compound curved sides. He wisely inquired about the viability of his design and we chatted about rolling and hammering metal, but nothing was going to produce the subtly required. I decided to try to adapt the industrial process of metal pressing to the tools available, 3D printers and a small hydraulic press. The first Image below is results of our first test. It worked so well, the student created a series of “die” models, we printed them and pressed his whole chess set. He then brazed 2 halves of each into the final cylindrical pieces. I was so impressed with the results that I began a test regime in the RPC to find the limits of the process. I created various pieces of a toy car as a test and the following photos show the results. I am now confidant with the process and can advise this process to future students and faculty.
The following images are another methodology I developed in the RPC. Its essentially a “lost-wax” casting using 3D printed plastic as the sacrificial form. It was carried out in the DAAP foundry and it was completely successful.