From the most complex details to the simplest designs, hobby modeling is a challenging but vastly rewarding undertaking. Casting your own models not only gives you an original design of your own making, but it also allows you to work on a project literally from the ground up. With enough practice and attention to detail and safety precautions, you can cast your very own works of art. Does this Spark an idea?
Instructions
Sculpting
1. Sculpt what you want to cast. Take some modeling clay, and work it so it is soft and malleable. Once you have done this, you can begin sculpting.
2. Shape a rough image of what you would like, then begin using your tools to detail out exactly what you want to create.
3. As you are sculpting, remember to keep it simple. If you are a novice, give yourself time to create more complex designs. Don't limit yourself to just sculpting tools. Items such as needles, small screwdrivers and knives do just as well as a set of regular tools.
4. Once you have crafted your sculpture, let it harden and dry. This will be the template for your mold.
Creating the Casting Mold
5. To create the actual mold, you will use vulcanizing silicone. There are two types you can use. One is familiar to most home owners in the form of regular silicone sealant. This is readily available at more hardware stores and is very durable for the abuse it will take as a mold. The downside to this type of silicone is that it cures very tough, making any after-curing adjustments very tricky. The second type is two part silicone. This is also an excellent type of silicone for mold making, however it is more difficult to find and more costly.
6. Make a box according to the size of the model you are casting. Give yourself about an inch to spare around each side of the model. Add in your silicone, filling the box about half way.
7. Coat the sculpture with a non-stick agent; typically this is petroleum jelly.
8. Press the sculpture into the silicone until it has been immersed halfway and let the silicone set.
9. Remove the model and coat it again with petroleum jelly. Allow the second half of the silicone to set.
10. Once you have your mold, create a few small vents for air and the expansion and contraction from the heated metal. Spots for these pockets are best made around the appendages of your model.
11. Put your mold pieces together and bind them with the mold clamps or wire ties.
Making your Model
12. You will be working with very high temperatures, so make sure you are working on a non-flammable surface and use your leather work gloves and protective eye wear. Set up your casting mold and all essential tools within easy reach.
13. Casting metal is actually a low temperature melting solder mixed with another alloy to make it the best possible product for casting. Look for solders that melt around 200 to 400 degrees Fahrenheit. Warm your melting pot only hot enough to melt your metal. Any hotter and it could scorch your mold.
14. You will also need to heat your mold. You can do this by going over it with several quick pours or you can heat it in an oven.
15. Once your metal is melted pour it into your clamped mold. Let it solidify for a few moments.
16. Carefully open your mold and remove your model. Be sure to use your leather gloves, as the model will still be extremely hot. Don't be worried if your model has excess pieces of metal on it; these are called flash and are unavoidable. Flash is easily removed with a small knife once the model has cooled.
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