Tech Artificer

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TA-02 · March 2025

Bus Token Award

The Nashville mayor’s office wanted an award to give to a student who rode every WeGo route. I cast it in solid aluminum from a 3D-printed model.

Design
Autodesk Fusion, from the mayor’s office’s designs
Materials
Aluminum from melted cans; iron-filled PLA stand
Methods
3D printing, sand casting
Status
Complete and awarded
The finished aluminum token on its stand: a Nashville skyline above a city bus, in relief.
The finished token, front

01Design

Using the mayor’s office’s designs, I laid out the token in Autodesk Fusion for personal use (opens in a new tab): the skyline and bus on the front, the inscription on the back.

Fusion model of the token front: Nashville skyline above a city bus.
Front, in Fusion
Fusion model of the token back: “Achievement Unlocked” with the recipient’s name, route note, and the year 2025.
Back, in Fusion

02Pattern and mold

I 3D printed a model of the token on an Original Prusa Mini+ (opens in a new tab) with Elegoo Rapid PLA Plus (opens in a new tab), then used it to make an impression in Petrobond fine casting sand (opens in a new tab) in an extra-large two-part sand casting flask (opens in a new tab).

The white 3D-printed model of the token on a cutting mat, with pegs for the casting channels.
3D-printed model
The printed model pressed into red casting sand in a steel flask.
Making the impression
A closed casting flask packed with red sand, ready to pour.
Ready to pour

03Casting

I melted a few dozen cans in a 12KG propane melting furnace to cast the token in solid aluminum.

The raw aluminum casting, front side, in a metal tub of water outdoors.
Front, fresh from the quench
The raw aluminum casting, back side with the inscription, still flecked with sand.
Back, fresh from the quench
The aluminum token on a disc sander table.
Cleaning up on the sander

04The stand

I designed a stand for the token and printed it on the Prusa Mini+ with Protopasta Iron-Filled PLA (opens in a new tab).

Fusion model of a curved cradle stand with a slot for the token.
Stand, in Fusion
The finished token on its stand, back side, showing the “Achievement Unlocked” inscription.
The finished token, back

The mayor’s office shared a video of the presentation: watch it on Instagram (opens in a new tab).