Lost PLA Casting: Lead Heart

What?!

A foray in to casting toxic heavy metals at home with no prior training nor experience. What could go wrong?

The ultimate goal is to be able to cast the model below in lead. The casting sprue will create a stand for this poisonous paper-weight.

Why?!

We still have a small pile of lead and previous attempts at open casting have failed, as evidenced below.

How (much)?!

The principle is similar to lost-wax casting, but with 3D printed PLA instead of wax. In short, we plan to:

1. Set the PLA mould in to casting media – this will be builders sand and a touch of cement.
2. Make a fire and melt the PLA from the mould.
3. Melt a pot of lead. Melting point of lead is 327 °C, so should be achievable with an open fire.
4. Pour the molten lead in to the mould.
5. Wait for the mould to cool and then break it out.

In regards to costs; the lead is obviously free, the mould housing was from some spare flat plate, the crucible is a recycled baked bean can and the fuel for the fire will be from old fence panels. Aside from a small amount of consumables this project will cost £0.00.

When?!

Soon, hopefully!

Where?!

The process will take place in the back garden.

As for the product… Let’s see what’s produced, before determining where it can be used.

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Feedback

Do you think this project idea is worth pursuing? Do you think this acorn of an idea could grow in to a mighty oak tree; or is it destined to become squirrel poop? Cast your vote below! Also feel free to leave any comments at the bottom of the page.