How to Make a Metal Casting
For centuries, one of the most popular method of making molds was using sand casting. A pattern is used to create a perfect negative in the sand. The hollow space is then filled with metal or glass or wax, depending on the needs of the caster. Sand casting today is used in manufacturing and of hobby metal casters.
Things You'll Need
- Metal for casting Green sand (foundry quality sand) Molding board Patterns (Items to be copied) Crucible Metal casting furnace Pouring shank
Instructions
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1
Take the patterns for the items you want to mold, and arrange them on the molding board. If you are casting several items, you will want the pattern for the runner system, which will be the path the metal runs along as it branches into the different molds.
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2
Tightly pack the molding board with the green sand, making sure to fill all the details of the pattern. Secure the top in place.
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3
Flip the molding board over. Carefully remove the bottom of the molding board. Next, remove the runner and patterns, being careful not to wiggle or disturb the pattern in the sand as you do so. Spoon out a pathway in the sand between the void left by the runner and the molds. You will want to make this wide enough so that enough metal will reach all areas of the mold before the metal cools.
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4
Position a block in the second mold board in the location so that when it is flipped over the block will match up with the central runner. Tightly pack the mold board with sand. Flip the mold board over and position it on top of the first mold. Remove the bottom and the block, leaving the pathway to the inside of the mold open and ready for the metal to be poured in.
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5
Using the metal casting furnace, melt the metal inside of a crucible. Hold the crucible with a pouring shank, and quickly, but carefully, carry it to the mold. Pour the liquid melt into the mold.
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6
Allow the metal to cool. Dig through the sand to gather the casted metal. Brush off all the loose sand.
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7
Trim off the excess metal tree that is attached to the molded items. Sand off the rough edges.
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Tips & Warnings
Always use caution when casting metal. Wear protective clothing and gloves.
