Lost Foam Casting a Aluminium House Sign // Part 2

Part 2 of this aluminium casting project is finally here. In the previous video, I CNC machined an XPS foam pattern to make a custom house number sign. In this video, I take that foam pattern and use lost foam sand casting to cast it in molten aluminium.

This is a full DIY metal casting process, covering sand preparation, foam pattern placement, pouring aluminium, and revealing the final cast. The result isn’t flawless, but that’s part of working with lost foam casting and home metal casting. This project is all about learning, experimenting, and having fun.

If you’re interested in CNC machining, aluminium casting at home, lost foam casting, or budget electric furnaces, this video shows what actually happens when theory meets reality. No perfect outcomes, just real results and real experience.

This video follows directly from part 1, so make sure to check that out if you want to see how the foam pattern was designed and CNC cut. Whether you’re into metal casting, CNC projects, or maker-style builds, this video gives a realistic look at the process from start to finish.