Elysium Max Exoskeleton

The first attempt at shell casting with the two chest plates has started. Sprued wax model:

First dip

Already developing cracks in the fist layer - most likely because the slurry needs more water

Second dip

Sprue planning for models to be cast using the shell casting process is more serious than with vacuum-assist casting, so I am performing at least two rounds of review with metal casting experts before proceeding:

https://github.com/01binary/sprue-planning/blob/master/chest-sprues.stl

https://github.com/01binary/sprue-planning/blob/master/hip-sprues.stl

The last 7 parts cannot be cast using the jewelry process due to geometry that requires a very heavy custom flask and tons of investment. The weight of the finished piece makes it nearly impossible to manipulate fast enough to insert into a vacuum chamber and pour metal in 20 seconds, before shell-shock.

I am going back to shell casting after some advice from The Home Foundry forums, and I will post a video after the first failed experiments.

Another 360 video of trying out the new vacuum chamber:

I exported my first long 360 video with immersive effects, transitions and composited 3D renders:

I've been working on a custom vacuum assist chamber for casting large parts:

I also got a 360 camera so now I can video blog & live stream the work on this project in VR. The editing should also be fun.

Lastly, I am continuing to make rubber molds for the remaining parts:

More two-part molds for chest plates. Casting them in metal will require welding a custom steel flask because they are the biggest parts I will have to cast yet.

Started a new two-part mold for shoulder connector heads:

A batch of four flasks with connectors & wrist clamps:

New vacuum setup with fixtures still working well:

Last week I re-cast two parts with better detail and completed four other parts I already had molds for.

I also started working on casting some of the largest parts: hip and chest plates

Left chest plate two part mold (probably just the first draft, as I am still learning how to make these)

I also ordered a new batch of risers with inline ceramic filters. 

Finally, I started working on an investment casting article. I want it to be the best reference for DIY investment casting on the Internet, so I'm taking time with reviews, edits, and graphics. Seeking feedback from anyone here:

https://github.com/01binary/investment-casting

I've achieved the highest quality casting results possible with my setup, so I am learning how to use a FlexShaft this weekend to finish parts after cutting them off the sprues:

Also casting wax parts to begin another metal casting batch: