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INTRODUCTION TO CASTING
The contents of this section of the site are set out in a [broadly] logical sequence (starting with PATTERNS and ending with a SUPPLEMENT that covers issues such as MATARIALS TESTING and RESTORATION). Individual topics within the site may also cross refer to earlier or later stages of the process.
The site covers the various casting processes in some detail, however there are a number of topics, summaries and technical terms that may be of particular interest to users with only a basic understanding of either the process or how to proceed with getting a casting made. These topics are highlighted (B) [BASICS],
Some of the illustrations are available only in the form of PDF files, these can easily be accessed via the relevant web page and viewed from within your web browser with the appropriate Acrobat PDF plug-in.
CASTING SITE MAP
Introduction to Patterns (B)
Types of Pattern/Lost Patterns (B)
Materials for Lost Patterns
Permanent Patterns
Materials for Permanent Patterns
Clay & Ceramics
Plaster Waste Moulds
Direct Plaster
Wood
Stone
Metal
Plastics & Resin
Preparing Master Patterns (B)
Fixing & Lifting Points
Sectioning Patterns
Enlargement
Cross Sectional Enlargement
Digital Enlargement
Master Pattern’s Summary (B)
Master Pattern Keywords (B)
About Reproduction Moulds (B)
Flexible Moulds
Flexible Materials
Plastics
Natural & Synthetic Rubbers
Latex
Vulcanised Rubber Dies
Synthetic RTV Elastomers
Polysulphide Rubber
Silicone Rubber
Polyurethane Rubber
Rigid Reproduction Moulds
Mould Construction/Impression Moulds
Pour Moulds
Blanket Moulds
Restrained Case Moulds
Mouldmaking Hints
Moulding Summary (B)
Moulding Keywords (B)
Wax (B)
Animal & Insect Waxes
Vegetable Waxes
Mineral & Synthetic Waxes
Wax Blends
Colouring Wax
A Brief Guide to Blending
Creating a Wax Pattern
Casting Waxes from Moulds
Building a Full Wax Thickness
Slushing
Wax Injection
Working with Patterns
Cores
External Core Armatures
Mould Stripping
Wax Retouching
Inspecting the Wax Pattern
A Summary of Common Wax Faults
Edition Numbers (B)
Monogram/Signature/Date/Foundry Marks (B)
Weighing Waxes
Preparing Waxes for Casting
The Pouring Cup
Metal Feeding & Venting
Runners
Direct & Indirect Runners
Risers (Vents)
Sand Venting
Drains
Core Vent
Core Pins
Core Prints
Supplying Waxes to a Foundry (B)
Waxworking Summary (B)
Waxworking Keywords (B)
Introduction to Investment (B)
Investment Materials
Common Features of Investment Moulds (B)
Plaster & Grog
Plaster & Grog Mixing
Ceramic Shell Investments
Ceramic Shell – An Overview
The Ceramic Shell System
Ceramic Shell Investing 1
Ceramic Shell Investing 2
Ceramic Shell Investing 3
Ceramic Shell Investing 4
Ceramic Shell Investing 5
Hybrid Investment
Jewellery Investments
Investment Summary (B)
Investment Keywords (B)
Kiln & Casting Introduction (B)
Wax Removal
Single Stage Burnout & Firing
Flash De-Waxing
Two Stage Burnout & Firing
Casting Introduction (B)
Melting & Pouring Metals
Furnaces
Fuels
Vacuum Casting
Centrifugal Casting
Kiln & Casting Summary (B)
Kiln & Casting Keywords (B)
Introduction to Metals (B)
Metals & Alloys (B)
Properties of Metals
Why Your Sculpture Cast is Probably Not Bronze (B)
Production Metals & Alloys
Copper & Copper Alloys
Gunmetals
Silicon Bronze
Phosphor Bronzes
Brasses
Nickel Silver
Aluminium Bronze
Nickel Bronze & Other Copper Alloys
Light Metals
Aluminium Alloys 1&2
Selecting an Aluminium Alloy
Zinc & Magnesium
Ferrous Alloys
Iron
Wrought Iron
Carbon Steels
Weathering Steels (Cor-Ten)
Stainless Steels
Noble Metals
Gold
Silver & Platinum
Lead
Tin & Nickel
Metals Summary (B)
Metals Keywords (B)
Finishing Introduction (B)
Fettling
Autograph Bronzes
Fine Finishing
Casting Faults 1
Casting Faults 2
Casting Faults 3
Reconstructing Cast Sections 1
Reconstructing Cast Sections 2
Reconstructing Cast Sections 3
Supports, Fixtures & Fittings
More About Structural Support Armatures
Fitting a Cast to an Existing Structure
Joining & Cutting
Welding & Brazing
Oxy Gas Welding
Oxy Gas Cutting
TIG Welding 1
TIG Welding 2
MMA Stick Welding
MIG Welding
Plasma Cutting
Studio Welding (B)
Introduction to Surface Finishing
Polishing
Protecting a Polished Finish
Patination
Applied Patination Processes
Surface Condition for Patination
Preparing a Surface for Patination
Preparing & Applying Patination Chemicals
Cold Patination
Hot Patination
Fume Patination
Buried & Covered Patination
Patina Finishing & Protection
Enhanced Wax Finishes
Alternative Protective Coatings
Gilding
Electroplating
Electropolishing
Anodising
Zinc Galvanising & Other Coatings
Metal Spraying & Bronzing
Enamelling
Antique Paint Finishes
Oil Paints
Commercial Paints
How To Get The Right Finish (B)
Finishing Summary (B)
Finishing Keywords (B)
8 INFORMATION (B)
Introduction to Information
Choosing a Foundry
Foundry Fees
Foundry Quotations & Estimates
Quoted Prices – What’s Included
Tendering & Price Negotiation
An Introduction to Sales and Arts Commissions
Pricing Your Artwork
Applying for Commissions
Budgeting a Commission
Fixed Budget & Fixed Fee Commissions
Contracts
Insurance
Public Liability
Copyright
Transport & Packing
Export
Installing Sculpture
Information Summary
Quotations Checklist
Information Keywords
Introduction to Sand Casting (B)
Master Patterns for Sand Casting (B)
Lost Patterns
Cast Surface
Permanent Patterns for Sand
Materials for Pattern Construction
Moulding Surfaces & Undercuts
Sand Patterns for Commercial Foundries
Commercial Patterns – Materials & Construction
Refractory Sands & Binders
Sodium Silicate
Green & Dry Sands
Air Set, Resin & Oil Bonded Sands
Shell (Croning Process)
Die Casting
Continuous Centrifual & Cuttlefish Casting
Electroforming
Sand Casting Summary (B)
Sand Casting Keywords (B)
Materials Testing
Introduction to Maintenance & Restoration
Maintenance 1
Maintenance 2
Restoration
What Goes Wrong with Metal Sculptures
Options for Restoration
Mechanical, Abrasive, Chemical & Electrolytic Cleaning
Finishing the Restoration
A Beginners Guide to Patination
Basic Patination Technique
Patina (Brown & Black)
Patina (Green)
Patina (Red)
Bibliography/Further Reading
Reference Notes 1-5