Step 1: Create the pattern
Before you make your mold, you must create a pattern to determine the mold`s shape. The pattern can be a 3-dimensional model of your final cast. When you are shaping your pattern, make sure you account for any anticipated shrinkage when the metal cools. Patterns may also be gated with sprues to allow the molten metal to flow into the mold.Step 2: Make the molds
After you have created a pattern, it is time to make your mold. Each of these methods for making molds are optimized for different casting metals and various levels of pattern complexity.
Step 3: Choose the metallic alloy
All metal castings are produced from either ferrous or non-ferrous alloys.
Step 4: Melt the alloy
Melting processes vary between alloys because each alloy will have a different melting temperature. Essentially, melting consists of placing the solid alloy in a crucible and heating it over an open flame or inside of a furnace.
Step 5: Pour into the mold
Pour the molten metal into the mold cavity.
Step 6: Remove the casting from the mold.
When the metal has cooled and solidified, you can remove it from the mold. If you cast into a single-use mold, you can break away the mold from the casting.
Step 7: Finishing
File and polish your solid metal cast! This may involve cleaning your cast metal object, like scrubbing away excess mold material in water, breaking off the casting gates with clippers for small objects, or even an angle grinder for large pieces.
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