After I built my foundry, I discovered how little I enjoy patternmaking. So, I began looking for easy ways to turn 3D models from Pro/E into solid patterns that could be cast. At first, my search was for a way to convert an inkjet printer into a stereolithography or rapid prototyping machine. I have used machines at school and at work that use a powder and an inkjet that shoots a binding agent. I didn't find anyone that had done this with a printer, but I found a better project...Homemade CNC routers!
There are many sites out there of folks that have built a CNC machine that uses a router or dremel tool to mill out 2D or 3D shapes in wood, foam, and some even do metal! I'm on my way to buiding one of these as well. The primary goal is to be able to mill out 3D foam patterns for lost-foam casting in aluminum.
I had planned to design and build my own machine using castings, and I will. However, for now, I am building a canned plan machine out of MDF to use as a learning tool and to make parts for the real thing.
