Aluminum Foundry

This metal-melting foundry was my first serious engineering project. I made it when I was 13 years old and melted aluminum cans into pure aluminum. Around that age, I decided to pour my energy into developing any project that pushed the boundaries of what’s possible or developed my understanding of some field. So, I followed a tutorial video from The King of Random YouTube channel and created a metal melting foundry. This project helped me intuitively understand the work needed to develop this type of project.

A soda can melts inside my small foundry.

Molding Initials

Initials I molded for each of my family members by pouring aluminum on a foam model embedded in sand.

With this foundry, I created Christmas gifts for my family where I carved a piece of foam, covered it in sand, and cast a mold of each of their initials. While doing so, I recognized problems with the foundry. Firstly, the tutorial suggested using half a fire extinguisher can as a crucible, but after doing further research into backyard DIY foundries, I decided to buy a proper crucible online. I also decided that burning charcoal was not a sustainable way of melting aluminum. So, I followed another tutorial and upgraded the foundry to use propane gas.

Foundry V2

My second foundry and the first item I ever designed.

After some time, the original foundry started to break apart. So, I decided to design my own foundry. I used granite blocks as a frame and designed a roof made of the same cement-like material as the first foundry. This roof had a hole in the center so I could drop aluminum cans in. I also designed a door in the front that would house a propane nozzle. I used grout to adhere the blocks and ceiling together. I then attempted to melt aluminum inside the foundry. Although I was successful, the can took too long to melt. Looking back, the granite and ground were likely conducting heat away from the foundry’s chamber. Furthermore, the top of the foundry had a hole that made dropping cans into the crucible difficult. Although the project was not a success, I realized the importance of thoroughly analyzing a design and justifying every design decision before pouring time, energy, and money into a project that may not work.

Light Length - High School