Learn Metal Casting with expert, Steven Spelman!

About the Artist

Steven Spelman has been a freelance artist for over 25 years.  Creating and  developing products for large companies such as Hasbro, Warner Brothers, Nascar, Marvel, and Discovery.  After 15 years in film you can see some of his creations in  Ant-Man, Guardians of the Galaxy 2, Will Trent, Vampire Diaries and many more.  

Steven’s work uniquely bridges modern technology with naturalistic themes, often exploring traditional and urban fairy tales. His art delves into subjects of morals, ethics, and global issues, reflecting his commitment to merging contemporary and classic influences in thought-provoking ways.

The intent of this class is to cover the basics of metal casting. This class will cover a comprehensive overview of the of following:

·        Basic Safety, materials, and practices

·        Basic Sculpting, materials, and tools

·        Tools for making the sand mold

·        Process for making the mold

·        Other materials for making molds and casting

·        Where tools and materials can be purchased

·        Pouring the metal into the mold

·        Cleaning up the casting

·        Finishing and options.

Introduction to Metal Casting

Cost for Non-members is $225.00

Cost for members is $200.00.

Mondays, 5:00pm-7:00pm

Two-hour class for 3 weeks

Class dates:

December 9th

December 16th

December 23rd

The $65.00 material fee is standard for both.
Student to contact artist to review the supply list and purchase supplies directly from the artist.
404-641-8719
spelman.steven@gmail.com

Safety: We will be working with basic sculpture materials, mechanical tools, and hot materials. Safety is our number 1 goal while learning the skills needed to cast basic metal shapes. This will involve,

·        Dust masks

·        Safety googles

·        Rubber Gloves

·        Fire Extinguisher

·        Ceramic Fiber Blanket

·        Leather Apron

·        Welding Gloves

·        Fire Bricks

Sculpture: We will be working in high density sculpting foam that can be purchased at Reynold Advanced Materials. It is not necessary to use this to make a master sculpture. Carved wax, wood, clay, or any other solid material can be used. As this is a two part mold there needs to be no undercuts, and a slight draft to your carving should be used. We have rotary tools, gouges, files, and blades that can be used to remove material from the foam.

Sand Mold: Metal casting can be done into a variety of molds. Today we are focusing on a medium grain casting sand. This will absorb the heat and can hold a good detail. A finer grain sand can hold better detail.

Casting sands come in course, medium, and fine grain. Either water based "green sand" or oil based casting sand. We are using oil based Petrobond, which is slightly more expensive, though it has a lower maintenance level. There are several options available from Amazon.com. The orange version is for nonferrous metals.

Other types of metal molds:

·        High Tempter Silicone molds (Pewter, Tin, Zinc, anything low temp.)

·        Ceramic Shell Molds (Aluminum, Brass, Copper, Bronze, Iron, or Steel.)

·        Sodium Silicate Molds (Aluminum, Brass, Copper, Bronze, Iron, or Steel.)

·        2 Sand Molds (Aluminum, Brass, Copper, Bronze, Iron, or Steel.)

Flask: The molding flask is comprised of two sides. The cope and drag. We start by putting crumbled sand into the cope and gently pushing it down. Building a flat surface to have an area to push the sculpted model into. Then we use a parting agent, I typically use baby powder, or talc. We brush this on and then use a small hand blower to clean off any excess. We then apply the drag to the second side and repeat the process. Once this is completed we separate the mold and remove the master from the mold and create all vents and sprues. After closing the mold we will clamp it shut.

Pouring: Aluminum melts at about 1200 f or 750 c. The crucible should be loaded about 50% with metal and heated. All additional metal should be preheated before being put into the molten metal. This will get rid of any moisture on the metal. We will use a graphite rod to stir the metal to reduce any air entrapment. Once this is complete we will pour the metal into the flasks and fill them. After this we will wait until it is solid and open it to confirm the casting came out well.

Cleaning up the Casting: We will use the rotary tools to cut the sprues and vents from the casting. Using sanding bits we will clean up and discuss polishing and sanding the casting.