How to Cast Aluminum Name Plates

You can melt aluminum to make name plates.

Aluminum is a lightweight but durable material that is difficult to scratch, mark or dent. As an inexpensive material, it is a good solution for making name plates. Although you can purchase ready-made name plates, this can be costly. With the right equipment, you can cast aluminum name plates of your own. This process can take several hours but once you have finished, you will have your own name plate to customize in any way you choose.

Things You'll Need

• 2 molding boxes
• Aluminum pieces
• 1 heat-resistant base with sprue holes
• 1 heat-resistant base with no holes
• 2 sprue pins
• Small saw or drill
• Casting sand
• Steel rod
• Pattern for the name plate
• Sieve
• Small trowel or spoon
• Small weights
• Small blow torch
• Fire bricks
• Heat-resistant ladle
• Heat-resistant stone stand
• Protective heat-resistant clothing
• Protective eye wear

Instructions

1. Place the top box on top of the base with sprue holes and insert the sprue pins into the base. Using the sieve, start to sift the sand into the box, ensuring there are no lumps.

2. Add enough sand to fill the box. Compress the sand with your hands as you proceed so it stays tightly packed in the box, especially around the sprues. Continue adding sand until it rises slightly above the top of the box.

3. Create small indents around the sprue pins by scraping some of the sand out using the trowel or spoon. Carefully remove the sprue pins without disturbing the packed sand. Your top box is now ready.

4. Assemble the bottom box by placing the second molding box on top of the base with no holes. Sieve the sand into the box in the same manner as the top box, pressing it down tightly with your hands.

5. Use the steel rod to even out the sand so it is at the same height as the top of the box. You can do this by scraping the rod across the top of the box. Press the pattern for the name plate into the sand so it makes a strong impression then remove it, leaving the imprint intact. Carefully place the top box onto the top of the bottom box with the sand surfaces touching and secure them with the weights.

6. Place the fire bricks on top of the stand and put the aluminum pieces into the ladle. Put on your protective clothing and heat the aluminum pieces with the blow torch at about 1,200 degrees Fahrenheit until they start to melt. When the aluminum is completely molten, pour the liquid into the top sprue hole so it fills the mold and starts to rise out of the other sprue hole.

7. Leave the aluminum to cool. This can take several hours; the molding box should ideally be left overnight. When the cast has set, remove the aluminum carefully from the sand mold as it could still be hot. You can now remove the sprues and finish the metal to prepare it for engraving.

Tips & Warnings

• Never place the molding box on a cool surface as any spilt aluminum will splatter, potentially causing injury. Instead, try placing it on an electric hob or similar heated surface.

References

• Technology Student: Preparing the Cope (Top Box)
• Technology Student: Preparing the Drag (Bottom Box)
• Technology Student: Heating and Pouring the Aluminum