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A project log for Elysium Max Exoskeleton

Exoskeleton suit replica from the movie Elysium in Autodesk Inventor, 3D printed and investment cast out of Aluminum

valVal 07/29/2017 at 22:080 Comments

I love new tools, especially ones that improve the process. After consulting with a jewelry teacher, I got a pressure cooker for steaming wax out of invested flasks:


The steamer collects the wax on the bottom as a large disc that looks like a vinyl and you throw the disk away (or re-melt) after a 2-3 hour steam cycle on hi. Flasks go in the kiln with wax already removed, and the only thing left to do is get the water out of investment so there is no scary fire or heavy black smoke.

I also contracted a welder to make two tall 4" flasks out of four short ones. This takes care of all the long parts in the suit, mostly arm bones. I will still need custom box flasks welded for the chest piece and the hips because those are tall and wide at the same time.


Since the major reason I still have defects are internal mold fractures, I got jewelry waxing tools to perform detailed cleanup on the wax parts before they are invested:


...another reason was that water still left in the investment if not completely evaporated during the 300 F step will start boiling at 700F and generate steam that will push its way out of investment pores and take pieces of surface detail with it, destroying cosmetic surfaces. For larger parts, 300 F has to be held longer.

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