How hard to cast something in copper?

Hecubus114

Hecubus114

Sr Member
RPF PREMIUM MEMBER
If I have absolutely NO experience with casting metals, is it a ridiculous thought to attempt casting something in copper? Only about 2 inches in the longest dimension?
 
I think for most people it is too dangerous and difficult to cast something in copper. It has a melting temperature of 1983 degrees. The piece you are trying to create if only 2 inches long may be able to be cast using fine jewelry methods inside a flask using investment. It really depends on the level of detail and sharpness the casting has to achieve to meet your expectations. If you don't need extreme sharpness and detail you could do a sand casting. Either way you have to be able to safely melt the copper at almost 2000 degrees... I can tell you pouring metal at these temps is not for the faint of heart and unskilled. You can end up with a trip to the emergency room in a hurry.
 
I would look for someone in my area who could cast it for me. There are artists everywhere who cast in bronze.

Have you ruled out cold-casting, or using metal-clay?
 
I was told the chest badges on Babylon 5 were made from pennies. The copper/zinc combo gave them their unique color. Melted them down with a blowtorch and poured into a vulcanized rubber mold if I recall correctly. Whatever you do research it thoroughly, use proper safety equipment, and ask a lot of questions because a burn can be for life.
 
Thanks for all the input guys - does anyone know if it's possible to plate resin with copper or something that looks the same?
 
TheSt.LouisKid said:
I was told the chest badges on Babylon 5 were made from pennies. The copper/zinc combo gave them their unique color. Melted them down with a blowtorch and poured into a vulcanized rubber mold if I recall correctly. Whatever you do research it thoroughly, use proper safety equipment, and ask a lot of questions because a burn can be for life.
Click to expand...

Isn't it a federal crime to destroy money? I remember someone told me that when i lived in NY ages ago...

Hecubus114 said:
Thanks for all the input guys - does anyone know if it's possible to plate resin with copper or something that looks the same?
Click to expand...

You can't plate resin (watch someone put up a link with a way to do it nowadays... :lol) but you can add metallic particles to make it look like metal (or also paint it with metallic paint).
 
Ronan87 said:
Isn't it a federal crime to destroy money? I remember someone told me that when i lived in NY ages ago...



You can't plate resin (watch someone put up a link with a way to do it nowadays... :lol) but you can add metallic particles to make it look like metal (or also paint it with metallic paint).
Click to expand...

You can plate resin parts, but you need to spray them with a high metalic content paint, first. There are special paints you have to use, with really high proportions of atomized silver to make them conductive enough to carry the electroplating current. I'll have to do some looking to find a link, though... ;)

*Quick edit*
For the OP, does the part have to be copper? Could it be cast in a lower-temp metal like zinc, or aluminum, or even a copper alloy like brass or bronze?
Some copper alloys can look a whole lot like pure copper, but flow better in the mold, and melt several hundred degrees cooler than pure copper. If you don't have to have the mechanical and electrical properties, plating copper over another metal would be way easier. Pewter can be cast into silicone molds, and melted with a plumber's propane torch.
 
Last edited:
It doesn't have to be copper, but what I am looking for is a plated or highly polished look. The piece I am trying to replicate is copper plated sterling silver.
 
Have you absolutely ruled out paint? Even just polishing up a thick coat of rattlecan enamel has given me decent results, especially on nice clean casts. I also work in metal and can say that paint and cold cast parts often look more 'real' than metal parts. (though not always). For the cost and effort of casting metal though you could do a few experiments with resins and paints using your original sculpt/mould, worst case you waste a small amount of time, best case you save a whole bunch of time.
 
Copper plating is actually fairly straightforward! I've done a bit of it for some jewelry pieces in the past. Here's a decent tutorial:

Copper Plating
http://www.instructables.com/id/EBYKQ12HSM50K0Q/?lang=en

I haven't tried this, but if the piece doesn't need to be large or sturdy, you could try casting it in solder, and then using a copper patina for solder. It looks like a company called Novacan makes an affordable copper patina. If you try it, let us know if it works!

Sent from my Nexus 5 using Tapatalk
 
I'd make a hi temp silicone mould & cast it in pewter, then get it plated in copper.

If you go for the resin you should be able to get it vacuum metallised.


HTH :)
 
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