making metal molds

Pastor Jedi

Well-Known Member
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Does anyone know how or know a source on how to make molds in order to pour metal into them?
 
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I have gone to a foundry and talked to them about sand and wax molding, but couldn't get anywhere. Anyone know of an easier way?
thanks
 
Many RTV Silicones can take the heat. Depending on the metal, and the volume of material. They don't last as long as when just casting resin though. Check with RTV dealer (Smooth-on and such), and I'm sure they can tell you the right product. Also, check out any local jewelers. They do metal pours in a very small scale for rings and such. They might be able to help you as well. Hope that helps.
 
I am in the middle of some bronze casting stuff right now.

I make wax positives and can take them to a local foundry.
 
A wax model can be coated in special plaster (not plaster of paris) or a reinforced ceramic slip. After the shell dries, the wax is burned out and metal is poured into the now hollow mold.

If you google investment casting, you should come up with some sites that go through the process, and even some small art foundries.

I can get you a bunch of links on ceramic shell investment casting, if you'd like.
 
Most college fine art programs have ceramic shell and bronze or iron casting facilites. Typically you can find someone at these schools to cast some work for you, like a student or resident artist, if you call the professor and ask them for a referral. Having work cast this way is usually at least half the cost of going to a commercial art foundry.

I've worked for art foundries and colleges, and I'd have to say going to a commercial art foundry should be your last resort.

You haven't really specified what it is that you're casting, I can understand if you want to keep your project under wraps, but they type of metal casting you will need is directly dependent on the size, shape, and complexity of what you want to have cast.

Is it bigger than a shoebox, or smaller? Is it hollow or solid? Is it smooth, or intricately detailed? Your answer to each of these questions can determine the best method of metal casting for your project.

If you need some discrete advice via PM, I'd be glad to help. I've got over 15 years in this field.. so I think I could point you in the right direction.
 
You haven't really specified what it is that you're casting,
Is it bigger than a shoebox, or smaller? Is it hollow or solid? Is it smooth, or intricately detailed? Your answer to each of these questions can determine the best method of metal casting for your project.
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It is a lightsaber that I made out of solid resin that was turned on a lathe.
 
It is a lightsaber that I made out of solid resin that was turned on a lathe.

You'll want it cast hollow, I imagine. What wall tolerance are you aiming for? Most casting processes can do hollow casts, but you will probably be limited to about 1/8" or 3/16" I'd recommend a ceramic shell investment.. not sure what metal color you're looking for, but you'll have some options with a ceramic shell mold, although it's mostly used for bronze.

They'll need a rubber mold of the piece, which they'll use to slush cast a hollow wax pull of the piece. If you don't already have a rubber mold, this is something you can do on your own to cut down your expense.

Essentially though I think you're in the size range that you could take this to a local fine art school if you have one. An art foundry would probably refuse this project unless you cast large quantities of these. Call a few sculpture professors at local art schools and ask them if they could refer you to a student or resident who could cast a small piece in metal for you.

You'll get good work cheap this way, and probably have a chance to be involved and learn a good deal about the process.
 
How do you do that?

It's called investment casting, or lost wax casting.

Your wax positive is made, by pouring wax into your silicone mold. After the wax hardens, and all the flash is removed, and it is polished smooth, it is then coated with porcelain grog, in a few layers, and let dry. This usually takes about 3 to 5 days depending on the piece in question. Then the mold is taken to the kiln, and baked until it is glowing red hot in order to completely dry out the mold, and burn out the wax.

The molten metal is poured into the mold, and then let cool. After it as sufficiently cooled the porcelain/plaster jacket is broken away from the metal, leaving you with a raw casting, which is then cleaned, and finished.

It's a pretty cool process.
 
Does it need to be actual metal - or just look like metal...?

Have you considered cold-casting, where you mix metal powder in with casting resin and then polish it afterwards to give it a metal looking finish?
 
Does it need to be actual metal - or just look like metal...?

Have you considered cold-casting, where you mix metal powder in with casting resin and then polish it afterwards to give it a metal looking finish?

Never heard of that either!
 
Some examples from items I made using cold casting, its Aluminum powder in hard urethane resin. You have to sand and polish it after you take it out of the mold. If you use steel powder you will get the weight of metal, and you can chrome it also.





 
This sounds interesting. I still have a couple wax carvings of Sinestro Corps rings I would love to have cast in metal. Even brass would be good.

Although I have never tried using brass powder in a resin cast before either. I never thought it would come out looking very good.
 
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