Materials Processing Studio Project

This project focused on learning to cast metal while utilizing our machining skills to manufacture a finished product.

For this project, we were given the option to 3D print our own custom hacksaw handles and cast them from aluminum. These castings were poured into ramed green sand molds, cleaned, and finished. The hacksaw blade holders were fabricated by turning rods on the lathe, facing and boring their interface blocks, their final curved profiles were CNC'd, and the parts were pressed together. The hacksaw spines were cut to length, peened by hand, and bent to shape. An interface slot was cut in the handle to accomidate the spine and the two were joined after drill pressing mating holes in the assembly. A slip for the blade holder was bent and spot welded to the end of the spine. Finally, the saw was bladed and ready for use.