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          Blender Tutorials: Designing a Casting - part 4

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Designing a casting. Part 4 Completing the Casting

With the location of the bolt holes, Keyway slots, adjuster housings and recesses now positioned all that remains is to build the face of the casting between the edges already modelled

However, to keep an organised mesh, it is necessary to build up a framework of edges, before auto filling individual areas.

Most of the parts we have created for the casting are not in horizontal alignment so a little bit of work is needed to provide vertices in the best location for the auto fill.
Casting parts

Slign vertices
Section off areas of the casting by extruding edges horizontally or vertically. Snap the cursor to existing vertices and in cursor select, Scale the other required vertices along their axis to 0 to align them.
Auto Fill

Use Auto Fill Shift-F in aligned regions. Beautify the fill Alt-F and convert trie's to quads Alt-J.

Organised reigeons
By constraining regions vertically and horizontally you can construct an organised mesh. The advantage of doing this are that if alterations are required to the model selection of aligned rectangles will be much easier than selecting areas of a mesh made up of disorganised triangles.

Y-axis support Before completing the face of the casting there is one other element that needs to be fixed to the X-axis slide. That is the support for the Y-axis.

As I have already roughed out my design I know the locating area for this needs to be 38mm wide.

The top section of the X-axis needs an area that the Y-axis can be bolted on to. To save having a left and right-hand X-axis casting I will incorporate the mounting on both sides of the casting.
Casting Inner Face As part of the casting's inner face I have incorporated a loop of faces around the outer edge, these will become a flange to help stiffen the casting and also give the mounting location for the Y-axis support bracket.

Extrude Extrude the holes and the outer edge back to give the casting thickness.

Once all the elements of the back face are on the correct alignment build faces between them in a similar manner to the front face.
Back View Because I haven't done any investment casting before I am not sure how thin the mould can be before it won't fill properly. Because of this I have increased the thickness behind the pockets to 4mm.

Extrude Flange Select the loop of faces from around the outer edge of the inner face. These will be extruded to provide a mounting point for the Y-axis and also offer some protection to the components of the X-axis.

Extrude the faxes 30mm to clear the V-rollers then cut clearance holes for the lead screw and guide shaft.
Completed Casting

Completed X-axis assembly This completes the casting for the X-axis of my CNC router. All that remains is for me to make a wax pattern, which will be fabricated, from templates printed at a scale of 1 to 1 from the Blender model.

This model is constructed at finished size. Extra metal will be required on the areas that are to be machined.

I will detail the progress of the casting in the Engineering section of this site.

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