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TK 109 Guru
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Joined: 11 May 2007 Posts: 712 Location: Galena, Ohio
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Posted: Mon Aug 27, 2007 1:06 pm Post subject: |
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nifty!
this is gonna be pretty cool!
i'm sure this isn't cheap? i mean, it actually sounds like i good idea for mold-making for stormtrooper armor, ect. as well. i'm sure plaster would work just as well for stormtrooper armor, though. that is, making a mold out of dense foam, or clay, and take a cast of that and a cast of the negative out of plaster..... _________________ -Alex
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vrogy Newbie
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Joined: 31 Jul 2007 Posts: 22 Location: in Sunny Florida!
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Posted: Tue Sep 04, 2007 2:22 pm Post subject: sharp LFMC |
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If you've been following along, you'll probably notice that last time I had the lost foam process working, but the edges of the cast part were rough.
Well, we've solved most of that.
Basically, we used a technique known as 'investment' to coat the foam with a high-quality finish that won't melt- in this case, ground drywall and clay.
The results still aren't flawless, and need finishing, but they're a lot better.
You can see here that most of the flaws on the V are how I cut it- by hand. Next time I guess I'll use an endmill in the drill press like the decepticon casting was done.
Another issue that's popped up is the porosity seen in the decepticon casting- I asked around on some casting forums, and apparently it's from gas bubbles forming in the melt, from impurities(mostly hydrogen). A quick solution is apparently to bubble argon through the molten aluminum, which is easy enough to do.
I've been plugging away at the CAD still, it looks like the first actual suit pieces we cast will either be some of the C.M.C.-400 boot fittings, or parts for the C-14 Impaler gauss rifle. |
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vrogy Newbie
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Joined: 31 Jul 2007 Posts: 22 Location: in Sunny Florida!
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Posted: Mon Oct 08, 2007 11:23 pm Post subject: |
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Oh wow, looks like I forgot to post updates here..
Well, let's see...
-got a site: http://vrogy.net/
-started on a CNC machine to cut all the special foam pieces on for casting.
these guts: http://www.hobbycnc.com/4aupc.php
these plans: http://rockcliffmachine.com/pictures.htm
motors, driver board kit
driver board assembled
power supply for the machine
-Progress on the gauss rifle CAD. I need something to motivate me on this.
Solidworks model
one of my reference images
-figured out how to hinge to suit, and if I'd fit.
From here:
-finish CNC machine
-finish gauss rifle CAD
-cast and assemble gauss rifle
-work on armor articulation prototype- wood 1X2 & plastic exoskeleton to test hinging theories. |
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CJanssen Expert
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Joined: 17 Feb 2007 Posts: 215 Location: Beaverton OR
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Posted: Mon Oct 08, 2007 11:31 pm Post subject: |
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Looks like great progress...keep up the good work. That suit is going to be awesome.
CJ _________________ "What, you think your some kind of Jedi?" |
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TK 109 Guru
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Joined: 11 May 2007 Posts: 712 Location: Galena, Ohio
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Posted: Tue Oct 09, 2007 1:59 pm Post subject: |
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...
...
um...
...
NICE!! ![Wink](images/smiles/icon_wink.gif) _________________ -Alex
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jegner Site Admin
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Joined: 30 May 2003 Posts: 2144 Location: Texas, USA
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Posted: Tue Oct 09, 2007 2:35 pm Post subject: |
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Oh, my!
Looking good! Are you going to CNC the suit? |
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vrogy Newbie
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Joined: 31 Jul 2007 Posts: 22 Location: in Sunny Florida!
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Posted: Tue Oct 09, 2007 4:22 pm Post subject: |
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jegner wrote: | Oh, my!
Looking good! Are you going to CNC the suit? |
Heh, thanks. I am indeed planning upon CNCing it, in an indirect way.
Basically, the idea is to CNC layered MDF molds for the vacuum-formed stuff, and foam for the lost-foam-metal-cast parts.
If you slow the cinematic Blizzard released down and take screenshots
You can see that the way it's made is with a frame that's bolted and welded together, which contains all the joints and hinges, and armor plates fastened on top.
Basically, the plan is to replicate that, using cast aluminum pieces bolted together for the frame, and vacuformed plates over the top which are mostly bolted in place. |
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vrogy Newbie
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Joined: 31 Jul 2007 Posts: 22 Location: in Sunny Florida!
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Posted: Fri Jan 30, 2009 6:49 am Post subject: |
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I've since..
-started a CAD model
-finished a CNC machine
pending are a finished CAD model and a more accurate CNC machine, possibly with a larger capacity- this one's limited to about 8X10X3" |
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jegner Site Admin
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Joined: 30 May 2003 Posts: 2144 Location: Texas, USA
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Posted: Fri Jan 30, 2009 7:21 am Post subject: |
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Awesome update! Wow! Great progress.
Jim |
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vrogy Newbie
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Joined: 31 Jul 2007 Posts: 22 Location: in Sunny Florida!
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Posted: Wed Feb 04, 2009 9:06 pm Post subject: |
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Just finished a CNC upgrade; from 1/4-20 threaded rod leadscrews to 1/2-10 acme leadscrews.
This allowed me to eliminate a whole bunch of backlash from the machine, and almost double travel speeds. Maybe I can get parts under 5 hours now.. |
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thomas bas
Joined: 22 Aug 2010 Posts: 2
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Posted: Sun Aug 22, 2010 11:06 am Post subject: |
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that's a coincidence: i'm just getting started on warhammer 40k armour. Starcraft is based on it, so I could learn a thing or two from you, eh? |
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croky_b Novice
Joined: 29 Dec 2009 Posts: 44
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Posted: Mon Aug 30, 2010 1:35 pm Post subject: |
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thomas bas wrote: | that's a coincidence: i'm just getting started on warhammer 40k armour. Starcraft is based on it, so I could learn a thing or two from you, eh? |
a double coincidence i'm just finish my W40K helmet
http://www.tk560.com/phpBB2/viewtopic.php?t=1581 |
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Benjaminvegeta Novice
Joined: 21 Feb 2010 Posts: 36 Location: Bavaria/Germany
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Posted: Mon Aug 30, 2010 2:59 pm Post subject: |
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Won´t the suit be extreme heavy in the end, if you build an aluminium exoskeleton? _________________ If it doesn´t exist, build it! |
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