Cheap welding & casting options for prototyping with aluminum/copper?

[TheWelder]

So, I have some prototypes sketched and I want them to actually exist, which is why I'm in dire need of a material. Upon canvassing online, I just realized that aluminum is the cheapest option that's also great for prototyping... But, I'm not really sure if that will work with the technique I have in mind, as I want to weld aluminum. I'm thinking of getting a TIG machine, but that's just too expensive! Thankfully I came across this forum and it has been really enriching in the few minutes I've been scrolling up and down. I read somewhere about green sand and lost foam casting but it's still shaky on me and I'm not sure how to distinguish between the two? Aside from that I am also thinking of exploring options like MIG and MAPP toorches. Any help on these topics would be very much appreciated...

 

[HandsomeBlueCollar]

it's common to weld aluminium, depending on how thick it is though. you can use arc welding sticks, also mig & tig for this work

 

[Honeymoon Ave.]

So, I have some prototypes sketched and I want them to actually exist, which is why I'm in dire need of a material. Upon canvassing online, I just realized that aluminum is the cheapest option that's also great for prototyping... But, I'm not really sure if that will work with the technique I have in mind, as I want to weld aluminum. I'm thinking of getting a TIG machine, but that's just too expensive! Thankfully I came across this forum and it has been really enriching in the few minutes I've been scrolling up and down. I read somewhere about green sand and lost foam casting but it's still shaky on me and I'm not sure how to distinguish between the two? Aside from that I am also thinking of exploring options like MIG and MAPP toorches. Any help on these topics would be very much appreciated...

Agree with @HandsomeBlueCollar, aluminum's great if you're doing prototype. But before anything else, practice casting first. You can move to welding when you're already confident with the shapes. After all if you want your visions to come to life you need LOADS of prep.

 

[Tinker.man]

So, I have some prototypes sketched and I want them to actually exist, which is why I'm in dire need of a material. Upon canvassing online, I just realized that aluminum is the cheapest option that's also great for prototyping... But, I'm not really sure if that will work with the technique I have in mind, as I want to weld aluminum. I'm thinking of getting a TIG machine, but that's just too expensive! Thankfully I came across this forum and it has been really enriching in the few minutes I've been scrolling up and down. I read somewhere about green sand and lost foam casting but it's still shaky on me and I'm not sure how to distinguish between the two? Aside from that I am also thinking of exploring options like MIG and MAPP toorches. Any help on these topics would be very much appreciated...

Alum is fine but welding it without TIG is a pain. MIG with a spool gun might get you there, but don't expect clean results without dialing it in and FYI, MAPP won't cut it.