Enlarging an Acorn 10x and Casting it with Bronze and Aluminum (Cast #132)

A tiny acorn is transformed into a giant metal masterpiece. The process is as follows: a 3D model is made using a technique called photogrammetry (taking lots of pictures of the subject from many different angles), separate models for the acorn cap and body in this case. The model is then 3D printed with wax filament and enlarged from the 0.5” inch diameter of the original acorn to 5 inches. Sprues and air vents are added to the wax models and they’re coated in many layers of ceramic slurry and silica sand to create a thick shell. The wax models are then heated to 1700F which vaporizes the wax and hardens the ceramic shell. Then the molten metal is poured in: 3.9 lb of silicon bronze for the cap and 1.9 lb of A356 aluminum alloy for the body.

I’ve been working to learn these techniques for quite a while. Initially, I was trying to enlarge more complex objects and struggling with it. So, I decided to go with a less complex object just to get experience.

The resulting cast….

Anthill Art Cast #132: Weight: 5.8 lb (Cap: 3.9 lb, Body: 1.9 lb), Height: 6 in , Diameter: 5 in

Photogrammetry:
291 pictures for cap
185 pictures for body

0:00 Intro
0:17 Making the 3D Models
0:49 3D Printing
1:15 Ceramic Shell
1:39 Casting
2:07 Breaking the Shells
2:34 Assembling
2:53 Finished Cast