@fillmon or someone that knows.

[Ichbin]

fillmon (Or anyone else that knows his crazy ass stainless steel technique.)

What kind of technique do you use to make the the molds?

[Maz]

lose the wax (http://en.wikipedia.org/wiki/Lost_wax)

[Olen]

Maybe... Lost wax isn't good for stainless but I'm not sure that filimons buttons are stainless. Certainly if you're thinking of it use tin or LEAD FREE solder. These are really easy to melt (you can melt them over a normal stove like filimon showed, stainless needs a reasonably good furnace). Make your model in anything which will melt styrofoam is good,some plasics can work as does wax (easiest and best).

Now set your model in something to pour the metal in. For low melting metals (ie tin, lead free solder) this can be plaster and plaster is easiest. Remember to leave a hole to pour metal into. This should be made of the same stuff as the model and be part of the model and left stinking out when you set the model in whatever (don't use cement). You may also need some sprues to allow gasses to escape, think about how you position them so the metal can get in and will fill the mould.

Now you have your model set put it in a small bonfire for a couple of hours. Now either while it is still hot or after its been in the oven on its hottest setting for a few hours pour the metal in.

Molten metal is very dangerous. Wear gauntlets, a face shield (NOT goggles, they won't protect your face and most likely the metal will go straight though them and destroy both your eyes; an untinted welding mask is suitable face protection), leather boots, and fire and heatproof clothing - a leather apron is preferable though not nessesary for low melting alloys. Melt your metal. A pan is fine for tin or solder, a bit of flux helps. Make sure molten metal NEVER gets near water, it will cause a stream explosion throwing molten stuff in every direction. Also keep it away from things which contain water, like cement, stones (they might appear dry...) and anything else you even suspect. Plaster also contains chemically bound water, thats why you burn it and make sure it is at least as hot as the metal you are putting in, that way steam explosions are less likely.

After you've poured let it set in the air overnight ideally or at least for several hours then crack it open and get to finishing. Also don't expect great results everytime.

So I've written almost enough to allow you to do it but not gone into details. Why? Because its dangerous. Research yourself. Know what to expcet and understand things a little better. Google is a good place to start. Put in say: home metal casting, perhaps, I don't know... :P The top site is reasonable and has links. I know your probably a bit irritated at me for not devulging everything but what if something slipped my mind? Burns aren't nice.

[Maz]

theres a guide section you should think of adding to olen.
Its not a how to, just guidance.
actually, you could probably just copy n paste your reply there!

+rep for insight

[Olen]

I'll look into it - if I do I'll write up a full blown guide over the next couple of days though I'm far from an expert (I don't do much apart from white metal casting).

EDIT - did you mean a new topic or an existing topic to add too? If the latter which one? I didn't know just anyone could write a guide...

Oh and I know its slightly OT but any ideas of a good thing to use as an example casting? I'll get someone to take photos

[Bucko]

I didn't know just anyone could write a guide...

Yep, if you can contribute, anyone can write a guide. Put it in the Metal Musings section of Tips, Tricks and Tutorials.

[jdbnsn]

any ideas of a good thing to use as an example casting?

Although it would not be easy, I would love to see an XBox 360 wireless controller cast from Stainless. On another note, filimon's casting are from stainless steel, he explains the composition in the Stainless Steel Mouse found in the "Completed Mod Gallery" in the "Peripherals" sub-forum.

[Zephik]

Although it would not be easy, I would love to see an XBox 360 wireless controller cast from Stainless. On another note, filimon's casting are from stainless steel, he explains the composition in the Stainless Steel Mouse found in the "Completed Mod Gallery" in the "Peripherals" sub-forum.

or... the XBox 360 itself? o.O

Man, when you think about it, there's so much stuff that would be really cool in stainless steel. I wonder how limited or unlimited this process is?

[jdbnsn]

True, how about something simple to start with like a USB jump drive or bluetooth dongle?

[Olen]

:gasp:

My word. What sort of kit has that guy got?! Stainless is the most horrific pernicity awkward and all round difficult metal man has come up with. Its expensive, quite high melting (~1400*C IIRC which is hot), doesn't like being cooked or stewed, hard to work... My word... Well thats well beyond most of us.

If I do a tutorial (and don't hold you're breath its too wet and I have no time) I'll limit myself to things anyone could do in their back garden with minimal equipment. So no stainless, just woosy white alloys.

[jdbnsn]

I'm holding my breath dude, would love to see that tutorial!

[Olen]

Really don't... I will get it done but I need some things first. Its wet here - ever seen horizontal rain? Not nice. I need someone to take photos of the actual cast, the only person I know who would be interested isn't availible... I'm also researching other methods which would be easier and currently only have lead based alloys and high melting things.

So maybe in the next two weeks. Depending on work and driving tests etc.