This article is amazing. Lost PLA casting in metal.
https://imgur.com/gallery/qDcyq18
Oh hey, I can actually comment on this! I've been following this thread for a while now in case I could add something substantive, since I took additive manufacturing as part of my grad school program and know a thing or two about 3D printing.
So the first thing to note is-- this is, indeed, pretty cool. Print qualities have improved to the point that you can reliably expect a print to come out not only decent, but watertight enough for investment processes. Didn't use to be that way. I will point out, though. There's better things than PLA for investment casting in the 3D Printing world. So for one-- you may notice in the burnout phase, he had to take his sweet time to remove as many carbon deposits as possible, and he got an unusable casting out of it because of that. You need to be very careful in your selection of PLA for investment casting-- different additives will modify its qualities on burnout and may make it take longer to perform the operation. To my knowledge, as long as you're using PLA you don't have to worry about it not burning out, but still, something to keep in mind. Also worth noting that he didn't use his support structures as sprues for his device-- likely because of their porous nature. Someone probably makes a PLA filament designed to be specifically super casting friendly but I have no idea which it is.
If anybody's looking at 3D printing as a tool specifically for investment casting, however, I would be remiss not to mention the fact that FDM printers are probably not your best choice. FDM printers are the ones that use filament. Instead, you're going to want to use an SLA or DLP printer for that. I saw a little bit of talk about them towards the beginning of the thread, but not much. There are specific castable resin blends that have been designed for investment casting, and they've been around for years. The reason they're better, typically, is because you get much higher resolution on them than you do with regular 3D printers, particularly with the SLA ones where you don't get pixel artifacts from your projections. The supports, also, can be used as sprues much more readily, though you might still have to fuck with your model or with your slicer. You can do some buckwild shit with SLA printers and casting. Though I should point out, since I haven't seen it mentioned here before--
the resin for resin 3D printers is cancer juice. I'm talking extremely toxic. Learn how to use it safely if you get one because that shit is no joke. Avoid skin contact with the resin at all costs until it is completely cured. Don't touch it without gloves when it comes out of the printer, don't touch it without gloves when it comes out of the solvent bath, don't put your hand in the solvent bath without gloves ever, don't pour the solvent bath down the sink-- make sure you've got the right KIND of gloves to handle this stuff, and only use a pair once. Wait until it's cured completely before handling it with bare skin, that's when it's safe. Don't drink out of anything you print in this method, either.
Lastly, I'd like to share another technique you can use to get metal parts with 3D printing that can work with FDM printers. There's metal-rich filaments out there that are designed to be put in an oven to burn out and sinter-- Filamet brand filament in particular makes their stuff around this principle. They've got bronze, copper, and stainless steel. The way it works is you've got a PLA matrix with 85% metal content. You have a burnout phase, then you raise the temperature until the part sinters together. This means that you're going to need a refractory to use as a support material in the kiln, as well as a kiln with reasonably high temperature, but if you get the timing right you can apparently get some good shit going. For making really structural parts, you'd probably want to find someone that does HIP, or Hot Isostatic Pressing, so in the long run the casting method would be more cost-effective for functional pieces, but the sintering method would probably be more convenient for metal pieces that are just for show. If you want to screw around with a more exotic metal selection, you could try GMASS filament that has tungsten in it, but the density they have tells me there's a lot more PLA in there than there is tungsten, and you kinda have to get really, really hot to sinter tungsten. So like... good fucking luck. It's also staggeringly brittle for what it is without sintering, but it has a metal-like weight to it and polishes up nice too, just like these other metal-rich filaments.
So yeah. Glad I could finally contribute to this thread! I can't really afford a printer right now so the best I can do is give advice now that I'm away from our campus' printers. So... I guess I'll be lurking around to see more of those.