Making strong parts or cast parts should be easy in 2019, right?
Well, just do it then.
I need a CNC machine to make aluminum parts, confronted with the prices out there for a good machine. I decided to make it myself. The Z axis has to hold a small router from Home depot, and that part holding that router need to be strong enough. So I 3D printed my own part, and made it into a solid.
Design your part, and print it fast with .3mm height layers, no support and just Brim. Drim is also optional, but I think it gives you another layer of containment from the liquid Alumilite or two part Resin Chemical, available in many stores (Walmart, Joann's, Hobby Lobby, or online).
Once your part is designed, export it as STL and open the Cura application (If that is what you use.). To print the part fast and with less gaps, set your settings to .3 MM layer height, .08 MM shell, .12 MM Bottom, 0% infill. (see pictures with all my settings)
At print time, try to catch the machine before it prints the top. Stop the printing at this time.
If it finishes, just make two 1/2" holes to pour the epoxy.
Make a small batch of epoxy in a cup (follow instructions on product packaging). The first batch should be enough, just to cover the bottom of your part. Then, make more as needed. Make small batches to continue to fill the part.(don't attend to fill the part, in one try; you may end with a mess.)
Also slow down in sections where the printer made errors with layers that required support.
It will leak, don't worry about that, you will be able to clean the part very nicely; once you're done.
Once done, clean the excess with a sharp tool and just scratch it off. Then sand the top smooth.
Spray paint or leave it be, you're done. Yay.y.y.
I welcome any comments or ways of improving this method of casting. Thanks!