Metal Casting Zone Info Blog

Ben Weissman asked:


It seems that metal beds are everywhere these days, some of the most affordable choices for bedding in the market. However, these were not always available, with ancient beds constructed from less sophisticated materials. In fact, the first documented of such materials being used for beds doesn’t appear until the Egyptian Empire. Of course, these weren’t created from the same materials from which affordable beds are today.

While commoners still slept on primitive beds of leaves and similar items, the Pharaohs of Egypt discovered advantages to sleeping on raised platforms, with parts constructed from precious metals. Tutankahmen, for example, slept on a bed constructed from ebony and gold. Aside from being the first metal beds, these were also probably the first platform beds.

While this same construction with gold, silver, and bronze was used for high-end beds during the Roman Empire in conjunction with feather or reed stuffed mattresses, design left metal behind in bed construction after this time until the late 18th century, at which time cast iron beds were combined with cotton mattresses to do away with the infestation of insects in the bedroom. From that time forward, metal bedroom sets became more popular among consumers, eventually becoming the less expensive option compared to other materials such as wood.

Children bunk beds are often some of the most commonly found bedroom furniture in metal today, since it needs to be replaced more often and parents don’t want to spend more than necessary on the furniture in these area. However, there are many other uses today for metal in the bedroom.

For example, you can find a variety of stylish metal headboards online which can be elegant or simple (or both), depending on your taste. These headboards can add quite a bit of personality and beauty to your bedroom design without emptying your wallet or bank account.

In design today, wrought iron beds have also become wildly popular, being both affordable and stylish, with contemporary straight lines and sharp angles. Of course, for those who enjoy a more traditional look, wrought iron can also be wielded into a less severe design into a more intricate, delicate look. Still, this metal is the current favorite for all sorts of items, from headboards to daybed designs. In fact, trundles are often constructed from this material as well. As you can see, metal in the bedroom has evolved severely from its original use but is still highly desired in today’s designs.

Brass Metal Casting

Kent Kelin asked:


Metal casting has endured through the ages since the time of Ancient Egypt, possibly longer. Since then small foundries have developed to meet the needs of the individual caster. There are several reasons that people choose to create their own home grown foundries. A top reason is the need to create parts and pieces that are no longer available on the market or that are just too expensive to purchase. Those who get into metal casting for this reason are usually interested in restoration projects, home improvement projects, or hobby building like model planes and trains. Artists are the other group that see metal casting as a cheap and easy way to create sculptures from small to large. Jewelers even use metal casting to create complex pieces that would just otherwise be impossible to create. Given the wide scope of metal casting there are several methods and techniques that have developed. For those new to metal casting or for those wanting to try some of these other methods may find it difficult to find information on your own. Luckily, there are several metal casting associations and groups that are more then willing to share information and exchange ideas, projects, and pictures of the goings on in the their home foundries. On the internet, metal casting associations and groups are either message boards full of casters where they can ask questions, post ideas, and pictures or are websites that are maintained by a set group of people offering general information and educational resources. Both of these types of websites are incredibly helpful to metal casters who can benefit from the educational purposes of some of the sites tempered with the real life applications and experiences of the message boards. There will be more industrial foundry and metal casting information than sites directed at the small home foundries. Industrial metal casting sites can be wonderful sources of information so do not skip by these. Use both small metal casting sites and industrial sites to your advantage. One of the most popular message board type sites for information is the Casting Hobby Group found through Yahoo Groups. This casting group was developed and maintained by experienced metal casters and enjoys a high amount of activity. This is a great place to go to for quick information and ideas not to mention photos and even furnace building plans. The Casting Hobby Group can be found at http://groups.yahoo.com/group/castinghobby/ The Association of Backyard Metal Casters is located at http://www.abymc.com/. This online metal casting association has an extensive membership complete with informative articles, forums, and even live chat. Of course, pictures are posted on the site to give visitors ideas about what other furnaces and foundries look like. Don’t worry if you’re foundry isn’t pretty, there actually doesn’t seem to be very many of them that are. Now, The American Foundry Society is mainly for the industrial metal casters and companies but they also promote information and education to consumers. The information provided on the site is great for anyone wishing to follow advancements in metal casting technology. There is even an online store. http://www.afsinc.org/ is the online home for the American Foundry Society. For the most part metal casting associations and groups exist on the local level more than a unifying force on the web. What does exist on the web is a great source of information, ideas, and insight. It is a great idea to join any of the groups you can in order to share and find knowledge.

Backyard Metal Casting

Kent Kelin asked:


Art casting is an ancient method of creating statues and sculptures that has been in practice in Meso-America, China, and Ancient Egypt since 2000 BC. The Greeks practiced it, so did the Romans, and pretty much any civilization with a strong interest in art. Bronze is an alloy of tin and copper that has been used to make weapons and sculptures since its discovery by man. Bronze is able to fill in the fine detail of molds making it very desirable to artists. When art casting, bronze is the alloy of choice since it is both beautiful and easy to work with. There are few examples of bronze statues left from antiquity since the alloy became scarce and many of the statues were melted down for weapons and other sculptures usually for new emperors or victors. The Lost Wax Casting process is the preferred method used when art casting. This process was used in ancient times to create bronze items. Small foundries like the type found in backyards, personnel workshops, and garages are able to use the Lost Wax Casting process with a certain amount of professionalism. Commercial foundries and professional art companies use the Lost Wax Casting process as well to create custom items and monuments. The process remains, essentially, the same since the ancient craftsmen who first pioneered the method. When used in commercial manufacturing or jewelry making, the Lost Wax Casting process is called Investment Casting. Art casting is one of the more enjoyable reasons to fire up the furnace and get into metal casting. While most think metal casting to be strictly limited to hobbyist and historical re-enactors, casting is a popular skill and craft used by a wide range of people for varying reasons. Artists see the need to have metal casting skills as it allows the artists to have direct control over the process instead of out sourcing it to a commercial foundry. Commercial foundries that specialize in custom pieces will often charge outrageous prices for their services. Art casting on your own is often times economical and just smart. The Lost Wax Casting process is rather simple when compared to other casting methods but it can be time consuming and attention to detail is important. The artists will start with an original piece sculpted from wax. The original can be made of other substances like clay or even metal but wax seems to be the easiest to work with. The original will be used to make the mold. If the piece to be cast is large, multiple molds will be needed. This is common in art casting and completely possible with the use of shims and keys that will allow placing the pieces together after the casting process easier. Most molds will be made out of latex or other materials to help transfer the fine detail into the mold cavity. The original is often destroyed during the mold making process upon removal. Molten wax is poured into the mold until the desired thickness is achieved.  When dry, this wax copy is removed and chased which rids the piece of imperfections and is used to combine the pieces.  You will place paths for the molten metal on the wax copy.  You will also place a cup or funnel at the top of the copy. This process is called spruing and is done in wax. A ceramic shell is placed around the copy. The shell isn’t really ceramic but a sand and liquid silica combination.  You will repeat this step until the shell is thick enough for the piece. You will then heat the item which will melt the wax inside. The wax runs out of the shell through the paths placed during spruing.  Then comes the part for the molten bronze. The bronze is poured into the top of the hollow shell. When cool you are going to remove the shell carefully to reveal the finished product. The bronze sculpture is chased, painted, and finished up however the artists choose. Art casting can be done with any metal or alloy. If you are going to use the Lost Wax Casting process then you do not have to stick with bronze. Try other metals until you receive the perfect look for your piece.

Metal Casting Forum

Kent Kelin asked:


Metal casting has endured through the ages since the time of Ancient Egypt, possibly longer. Since then small foundries have developed to meet the needs of the individual caster. There are several reasons that people choose to create their own home grown foundries. A top reason is the need to create parts and pieces that are no longer available on the market or that are just too expensive to purchase. Those who get into metal casting for this reason are usually interested in restoration projects, home improvement projects, or hobby building like model planes and trains. Artists are the other group that see metal casting as a cheap and easy way to create sculptures from small to large. Jewelers even use metal casting to create complex pieces that would just otherwise be impossible to create. Given the wide scope of metal casting there are several methods and techniques that have developed. For those new to metal casting or for those wanting to try some of these other methods may find it difficult to find information on your own. Luckily, there are several metal casting associations and groups that are more then willing to share information and exchange ideas, projects, and pictures of the goings on in the their home foundries. On the internet, metal casting associations and groups are either message boards full of casters where they can ask questions, post ideas, and pictures or are websites that are maintained by a set group of people offering general information and educational resources. Both of these types of websites are incredibly helpful to metal casters who can benefit from the educational purposes of some of the sites tempered with the real life applications and experiences of the message boards. There will be more industrial foundry and metal casting information than sites directed at the small home foundries. Industrial metal casting sites can be wonderful sources of information so do not skip by these. Use both small metal casting sites and industrial sites to your advantage. One of the most popular message board type sites for information is the Casting Hobby Group found through Yahoo Groups. This casting group was developed and maintained by experienced metal casters and enjoys a high amount of activity. This is a great place to go to for quick information and ideas not to mention photos and even furnace building plans. The Casting Hobby Group can be found at http://groups.yahoo.com/group/castinghobby/ The Association of Backyard Metal Casters is located at http://www.abymc.com/. This online metal casting association has an extensive membership complete with informative articles, forums, and even live chat. Of course, pictures are posted on the site to give visitors ideas about what other furnaces and foundries look like. Don’t worry if you’re foundry isn’t pretty, there actually doesn’t seem to be very many of them that are. Now, The American Foundry Society is mainly for the industrial metal casters and companies but they also promote information and education to consumers. The information provided on the site is great for anyone wishing to follow advancements in metal casting technology. There is even an online store. http://www.afsinc.org/ is the online home for the American Foundry Society. For the most part metal casting associations and groups exist on the local level more than a unifying force on the web. What does exist on the web is a great source of information, ideas, and insight. It is a great idea to join any of the groups you can in order to share and find knowledge.

Foundry