Figured I'd introduce myself as I've lurked here for a long time but never posted due to not having anything to add till now. I've written a 20,000 word article over the very basics of foundry work and what I think would be important for anyone new to it to know. It's still under construction but I've put over 200 hours into it already in the last 3 weeks and I just want to get it out there for now. It's complete with common foundry terms and equipement, Ever casting method possible and I detail out the qualities of refractory sand vs molding sand and the science behind sand and what makes them useful for what scenarios. I also go into the history of every casting method complete with historical stories and the progression of patents and technologies that brought us to the foundry works we know today. It might be a be elementary for this forum but you might find the history parts entertaining and some of the sand science useful. Again it's still incomplete and if you find anything I've gotten wrong let me know and I'll revise it. It's designed more so as a glimpse into ever industrial method with DIY in mind, rather than a DIY tutorial for newbies. Currently all my experience is in industrial settings so I don't feel comfortable advising DIY much. you guys probably know way more than I do when it comes to that.
Now I should probably explain who i am. I'm Garen, if the url didn't give it away lol, I've worked at my families aluminum foundry and CNC shop, Phillips Patterns & Castings, since i was 15, currently 27. This year I've quit my family's foundry to pursue my own path of financial independence via e-commerce, freelancing and entrepreneurship which is a fancy way to say I'm working out of my house and unemployed. I'm a trained pattern maker from my father and uncle who have a combined experience of 100 years and they were trained by my grandfather who has been one since the 1930's. They are all trained in traditional mahogany pattern making without the use of CNC machines but my uncle was a life time pattern maker up until 65 with the use of CNC's and CAD/CAM. Today I mostly used FDM 3D printers to create patterns for use to make cast matchplates or mounted directly to BB plywood. But I can also program CNC machines for pattern work as well as high speed 4th axis machining of aluminum and steel fixture making. In 1947 my grandfather founded Phillips Patterns at the age of 19 in his chicken coop and it has grown into what you see today in my videos. As for videos, part of my new career change is being an industrial videographer. Along with making my own videos, website, articles and products to try and make money I'll also be traveling around to various companies and showcasing the industrial side of how things are made. I'm a huge fan of the old shows like "How Things are Made" or "how Things Work" but being in the industry I always felt they missed out a lot as the hosts don't actually know how any of the stuff works. I've grown up around green sand, air set, permanent mold, die casting and CNC machining as well as studied metallurgy and refractory science on the side so I'm hoping that experience and knowledge will help me out in not only showcasing company's but also going into detail on the science, history and methodology of whatever it is I'm videoing and not just be eye candy. But eye candy is always nice. Long term I'm looking to advise and help customers and businesses connect as well as bring some more industrial grade materials and methods to the DIY community if possible. I was laid off for 6 months back in the 2008 recession and my family's company almost went under because of it. Part of making these videos is not just to be an entertaining but to also help rebuild and educate people on all the stuff lost in the the destruction of manufacturing we saw these past 10 years.
Here is one of my first videos showcasing a Tool & Die shop. This company has been making our die cast molds for almost 20 years now and started out by making the molds for Tippmann paintball guns. So if you've ever played paintball at a field, you've probably personally handled a casting from my company. If you played around 2008-2011 there's a 90% chance I handled the gun you used as well. We are currently installing a 600 ton die cast machine in the building and a very awesome mold is being put on it but i can't talk about it yet and I'm not sure if I'm going to even be able to show it.
This video is a short 5 minute one that showcases the production level green sand foundry of my family's shop. I worked here for about 2 years total doing everything from molding, pouring, knockout, air set molding and pattern making.
Upcoming videos are going to be on refractory science as well as probably showcasing my family's gating methods and maybe some history of foundry. First I need to finish my website though. If you have any questions feel free to ask on here or just shoot me a pm on here or any of my social.