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Posted by James Waldby on April 10, 2008, 3:43 am
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I got an email pointing at an interesting site about sculpting
metal by a method analogous to fast-prototyping-in-plastic machines,
but in stainless steel + bronze. See link to exone and description
in the second half of http://www.bathsheba.com/sculpt/process/ .
Links from exone refer to casting cores and molds direct from CAD.
(Of course, for many molds using a CNC machine shop might be better.)
Briefly, the bathsheba page says, "work up the design using CAD
software", then at exone "the design is laid down, one layer at a
time, in stainless-steel powder held in place by a laser-activated
binder", "the whole model is built up," "extra powder is shaken off,
the piece goes into an oven, where heat drives off the binder and
fuses the steel powder", producing a "porous steel part that's about
60% dense", then the amazing part: "the stems are dipped in a crucible
of molten bronze, and capillary action causes the bronze to wick
throughout the piece" and "the end result is a composite metal that's
fully dense, with properties intermediate between steel and bronze.
It can take a polish or a patina, developing either rust (on the steel)
or verdigris (on the bronze)".
-jiw
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Posted by cavelamb himself on April 10, 2008, 5:57 am
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James Waldby wrote:
> I got an email pointing at an interesting site about sculpting
> metal by a method analogous to fast-prototyping-in-plastic machines,
> but in stainless steel + bronze. See link to exone and description
> in the second half of http://www.bathsheba.com/sculpt/process/ .
> Links from exone refer to casting cores and molds direct from CAD.
> (Of course, for many molds using a CNC machine shop might be better.)
>
> Briefly, the bathsheba page says, "work up the design using CAD
> software", then at exone "the design is laid down, one layer at a
> time, in stainless-steel powder held in place by a laser-activated
> binder", "the whole model is built up," "extra powder is shaken off,
> the piece goes into an oven, where heat drives off the binder and
> fuses the steel powder", producing a "porous steel part that's about
> 60% dense", then the amazing part: "the stems are dipped in a crucible
> of molten bronze, and capillary action causes the bronze to wick
> throughout the piece" and "the end result is a composite metal that's
> fully dense, with properties intermediate between steel and bronze.
> It can take a polish or a patina, developing either rust (on the steel)
> or verdigris (on the bronze)".
>
> -jiw
>
Wow.
That dude did some serious warpage to the space-time continum.
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Posted by Ed Huntress on April 10, 2008, 6:25 am
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> James Waldby wrote:
>
>> I got an email pointing at an interesting site about sculpting metal by a
>> method analogous to fast-prototyping-in-plastic machines, but in
>> stainless steel + bronze. See link to exone and description in the
>> second half of http://www.bathsheba.com/sculpt/process/ .
>> Links from exone refer to casting cores and molds direct from CAD.
>> (Of course, for many molds using a CNC machine shop might be better.)
>>
>> Briefly, the bathsheba page says, "work up the design using CAD
>> software", then at exone "the design is laid down, one layer at a time,
>> in stainless-steel powder held in place by a laser-activated binder",
>> "the whole model is built up," "extra powder is shaken off,
>> the piece goes into an oven, where heat drives off the binder and fuses
>> the steel powder", producing a "porous steel part that's about 60%
>> dense", then the amazing part: "the stems are dipped in a crucible of
>> molten bronze, and capillary action causes the bronze to wick throughout
>> the piece" and "the end result is a composite metal that's fully dense,
>> with properties intermediate between steel and bronze. It can take a
>> polish or a patina, developing either rust (on the steel) or verdigris
>> (on the bronze)".
>>
>> -jiw
>>
>
> Wow.
>
> That dude did some serious warpage to the space-time continum.
Metal rapid-prototyping methods have been around for a while, including one
that's similar to this method, introduced by Extrude-Hone back around 2000
or so. It uses a CAD program (through STL output) to lay down the metal
powder in layers, with a polymer binder, which is then sintered together
into a 3D shape.
As for copper-alloy infiltration of porous PM parts, you may have some of
them in your shop. B&D and DeWalt were making the bevel drive gears for
their angle-head grinders that way at least as far back as 1997. And a lot
of automotive parts are made the same way.
This is not to knock this particular development, but it's not really a new
idea.
--
Ed Huntress
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Posted by cavelamb himself on April 10, 2008, 10:06 am
Please log in for more thread options Ed Huntress wrote:
>
>>James Waldby wrote:
>>
>>
>>>I got an email pointing at an interesting site about sculpting metal by a
>>>method analogous to fast-prototyping-in-plastic machines, but in
>>>stainless steel + bronze. See link to exone and description in the
>>>second half of http://www.bathsheba.com/sculpt/process/ .
>>>Links from exone refer to casting cores and molds direct from CAD.
>>>(Of course, for many molds using a CNC machine shop might be better.)
>>>
>>>Briefly, the bathsheba page says, "work up the design using CAD
>>>software", then at exone "the design is laid down, one layer at a time,
>>>in stainless-steel powder held in place by a laser-activated binder",
>>>"the whole model is built up," "extra powder is shaken off,
>>>the piece goes into an oven, where heat drives off the binder and fuses
>>>the steel powder", producing a "porous steel part that's about 60%
>>>dense", then the amazing part: "the stems are dipped in a crucible of
>>>molten bronze, and capillary action causes the bronze to wick throughout
>>>the piece" and "the end result is a composite metal that's fully dense,
>>>with properties intermediate between steel and bronze. It can take a
>>>polish or a patina, developing either rust (on the steel) or verdigris
>>>(on the bronze)".
>>>
>>>-jiw
>>>
>>
>>Wow.
>>
>>That dude did some serious warpage to the space-time continum.
>
>
> Metal rapid-prototyping methods have been around for a while, including one
> that's similar to this method, introduced by Extrude-Hone back around 2000
> or so. It uses a CAD program (through STL output) to lay down the metal
> powder in layers, with a polymer binder, which is then sintered together
> into a 3D shape.
>
> As for copper-alloy infiltration of porous PM parts, you may have some of
> them in your shop. B&D and DeWalt were making the bevel drive gears for
> their angle-head grinders that way at least as far back as 1997. And a lot
> of automotive parts are made the same way.
>
> This is not to knock this particular development, but it's not really a new
> idea.
>
> --
> Ed Huntress
>
>
I'm not questioning the technology.
But take another look at that art-part he made!
There is some seriously convoluted mathmatics there...
Richard
--
(remove the X to email)
Now just why the HELL do I have to press 1 for English?
John Wayne
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Posted by Ed Huntress on April 10, 2008, 10:20 am
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> Ed Huntress wrote:
>
>>
>>>James Waldby wrote:
>>>
>>>
>>>>I got an email pointing at an interesting site about sculpting metal by
>>>>a method analogous to fast-prototyping-in-plastic machines, but in
>>>>stainless steel + bronze. See link to exone and description in the
>>>>second half of http://www.bathsheba.com/sculpt/process/ .
>>>>Links from exone refer to casting cores and molds direct from CAD.
>>>>(Of course, for many molds using a CNC machine shop might be better.)
>>>>
>>>>Briefly, the bathsheba page says, "work up the design using CAD
>>>>software", then at exone "the design is laid down, one layer at a time,
>>>>in stainless-steel powder held in place by a laser-activated binder",
>>>>"the whole model is built up," "extra powder is shaken off,
>>>>the piece goes into an oven, where heat drives off the binder and fuses
>>>>the steel powder", producing a "porous steel part that's about 60%
>>>>dense", then the amazing part: "the stems are dipped in a crucible of
>>>>molten bronze, and capillary action causes the bronze to wick throughout
>>>>the piece" and "the end result is a composite metal that's fully dense,
>>>>with properties intermediate between steel and bronze. It can take a
>>>>polish or a patina, developing either rust (on the steel) or verdigris
>>>>(on the bronze)".
>>>>
>>>>-jiw
>>>>
>>>
>>>Wow.
>>>
>>>That dude did some serious warpage to the space-time continum.
>>
>>
>> Metal rapid-prototyping methods have been around for a while, including
>> one that's similar to this method, introduced by Extrude-Hone back around
>> 2000 or so. It uses a CAD program (through STL output) to lay down the
>> metal powder in layers, with a polymer binder, which is then sintered
>> together into a 3D shape.
>>
>> As for copper-alloy infiltration of porous PM parts, you may have some of
>> them in your shop. B&D and DeWalt were making the bevel drive gears for
>> their angle-head grinders that way at least as far back as 1997. And a
>> lot of automotive parts are made the same way.
>>
>> This is not to knock this particular development, but it's not really a
>> new idea.
>>
>> --
>> Ed Huntress
>
>
> I'm not questioning the technology.
>
> But take another look at that art-part he made!
>
> There is some seriously convoluted mathmatics there...
Ha! Yes, it's pretty Mobius strips and Klein bottles, more or less. Very
nice.
BTW, I see that the technology is the one I was talking about. The company
is now called "Ex One." It's the old Extrude-Hone Prometal system. I took a
photo of one of their seriously convoluted demo parts for _Machine Shop
Guide_, I think it was, back at IMTS 2000.
--
Ed Huntress
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> metal by a method analogous to fast-prototyping-in-plastic machines,
> but in stainless steel + bronze. See link to exone and description
> in the second half of http://www.bathsheba.com/sculpt/process/ .
> Links from exone refer to casting cores and molds direct from CAD.
> (Of course, for many molds using a CNC machine shop might be better.)
>
> Briefly, the bathsheba page says, "work up the design using CAD
> software", then at exone "the design is laid down, one layer at a
> time, in stainless-steel powder held in place by a laser-activated
> binder", "the whole model is built up," "extra powder is shaken off,
> the piece goes into an oven, where heat drives off the binder and
> fuses the steel powder", producing a "porous steel part that's about
> 60% dense", then the amazing part: "the stems are dipped in a crucible
> of molten bronze, and capillary action causes the bronze to wick
> throughout the piece" and "the end result is a composite metal that's
> fully dense, with properties intermediate between steel and bronze.
> It can take a polish or a patina, developing either rust (on the steel)
> or verdigris (on the bronze)".
>
> -jiw
>