Here's A Neat Trick – Need A Part Or Object Made Out Of Aluminum?
If you start with a Styrofoam pattern you can cast aluminum object at your own foundry.
The next page will show how to melt the aluminum but now we need to make the mold to pour the aluminum into.
That's as easy as embedding your Styrofoam pattern into a bucket of sand.
Watch the video to see how it's done
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I assume the sand you use to cast would be reusable? If not, it’s not that big of a deal, but I figure I could save on waste.