I got interested in lost foam because of my grandson wanting to try casting. Over the weekend I was working on a design for a CNC router for the school FIRST robotics club and it suddenly dawned on me that a collection of aluminum parts carefully machined and assembled with a ton of bolts could easily become a single casting! It would be stronger with no joints, and glued together pieces of foam would allow me to remove material from places that can’t be reached for machining of the metal. I have already redesigned the router motor mount and the Z axis slide it bolts to. I will leave the castings rough except for the places it needs to be machined for mounting purposes. My CNC mill is tiny so eliminating lots of machining of metal saves a lot of time. This should be really cool.
