Prototype Metal Parts Cheaply with 3D Printing and Casting

Need a metal prototype but have a shoestring budget? Combine 3D printing with casting. Print your part in PLA filament, then use it as a lost pattern for investment casting. This method yields durable metal parts without CNC or tooling costs.

Start by designing your part with casting-friendly features: avoid sharp corners, include draft angles, and keep wall thickness consistent. Print the model with 100% infill to ensure it burns out cleanly. For the mold, mix plaster of Paris with fine sand (30-70 ratio) and add 2% salt as a hardener. This cheap refractory can withstand aluminum or brass pouring.

Burn out the PLA at 600°F (315°C) in a kiln or makeshift furnace—a charcoal grill works for small parts. Then preheat the mold to 500°F (260°C) before pouring molten metal. Finish the raw casting with files, sandpaper, or a Dremel. No fancy equipment needed.

This approach lets you iterate designs for under $5 per part. It's not production-grade, but perfect for testing fit, function, and aesthetics. Once validated, you can commit to more expensive processes.

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