As a Senior Pappalardo Apprentice, I designed a camelback straightedge that I am fabricating out of cast iron. I designed the pattern to be machined out of foam and packed a two-part flask with green sand onto the pattern halves. Mike Tarkanian of the MIT Foundry and Forge poured the cast iron into the flask, after which I broke it out and post machined the flat surfaces. The final steps are the surface grind and then hand-scrape the flat, both of which I will be doing over the coming weeks.
CNC milling the pattern out of foam.
Packing the flasks and cutting the runner, gates, sprue, risers, and vents.
The cast iron pour, done by Mike Tarkanian of the Forge, and the results.
After cutting off the excess iron and sandblasting.
Results after machining and grinding down the straightedge!