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wulfdesign

Peace Symbol Medallion (in Bronze)

by wulfdesign Feb 3, 2011
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Can you tell us your casting process? This is so cool.

quick and dirty explanation of the casting process.

CAUTION!: not responsible if anyone hurts themselves working with molten metals over 1500 F. this can be dangerous if not handled properly. make sure you ALWAYS wear proper casting gear (leathers, face shield, cap, welding gloves, all arranged so if molten metal flies it runs OFF you and NOT INTO
your clothing), work area is fire proof and ESPECIALLY do not have any standing water around during the casting process (molten metal + H2O = explosive steam and molten metal flying).

Design parts that have at least 1.5mm-2mm for best casting.

1) Clean up part of threads and any imperfections you
don't want to show up
(mainly bumps and strings).

2) Dip plastic part in hot casting wax and wipe off excess while still hot.

3) after wax solidifies wipe off again with paint thinner to clean up surface but still show underlying texture.

4) sprue http://en.wikipedia.org/wiki/Sprue_(manufacturhttp://en.wikipedia.org/wiki/S...
ing) up your part

5) dip in binder agent, then ceramic shell, let dry. repeat 7-8 times over several days.

6) burn our wax / ABS and fire ceramic shell in outside furnace until your kiln sides are starting to glow white. let cool.

7) melt bronze in crucible. preheat ceramic shell mold, pour molte
n bronze into shell, let cool (now is a good time for beer or two).

8) break ceramic shell off metal parts (works best if you bang on the sprue system only and let vibration break out your part rather than chance mashing your parts up).

9) cut parts off sprue system with cut off disk or better yet
hack saw blades work better (use air powered).

10) grind off final bits of sprue system and polish up part. I did the final bit of polishing with a brass brush but most people use power tools.

11) patina to taste (I didn't do that part yet).