Another boring post about my casting experiments I'm afraid ;)
A few posts ago Wayne asked about casting metal. I found a source of ground metal dust (it is used in colouring glazes for potting). I have bought copper, brass and aluminium to play around with. I can also get iron & bronze. This stuff is expensive (£5-£20 per 500g depending on the metal), but I like the results!
This is a 2x2x4 extension cubie, cast from a clear polyester with 2:1 by weight copper dust added. I would add 3:1 next time (this does mean using a lot of this expensive stuff per puzzle). I had to use polyester because I don't have clear polyurethane, I will be getting some!
The piece feels cold like metal, and is heavy. It is also very hard, I don't have a durometer but it is much harder than even a 90 shore epoxy. It polishes up like copper also.
Clearly I wouldn't make a 2x2x4 from these metallised resins, that's just a mould I had handy for the experiment. I am making moulds for a rhombicuboctahedron, this would look very nice with copper, aluminium and brass layers!
Wayne, I really think you could cast an injection moulding tool with an aluminium metallised epoxy resin! I am very sure it would work with a low pressure hand pumped system!!