Plaque Buildup: Bronze Casting from Laser-Cut Forms
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Laser-cut Form for Bronze Casting
Here are some pictures and notes from a test of a bronze casting using forms produced on a laser-cutter. This is a casting of a plaque with text, produced first by engraving into a 1/2″ deep piece of acrylic using a laser cutter. The acrylic form is used to create a negative mold in casting sand, which can then accept molten bronze.
This was a really cool project and seems to be successful. I’m hoping to continue and try some more interesting forms beyond text. I think cutting-edge fabrication technology is at it’s best when combined with established/non-digital techniques–it’s the best of both worlds!
This pour took place at the Butler Street Foundry in Chicago.
![](http://s93876915.onlinehome.us/chris-reilly_dotorg_WP-2013/wordpress/wp-content/uploads/blog.145.jpeg)
The Final Product: A Cast Bronze Plaque
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A Deep Raster Engraving With a Tapered Shoulder Makes for a Great Plaque Form
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A Two-part Sand Mold Will Recieve the Molten Bronze
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Casting Sand Packed into the Mold Holds an Impression of the Laser-cut Form
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Casting Sand is a Mixture of Sand & Clay; Imagine the Best Sand-Castle Sand, Times Ten
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A Gas Furnace is Used to Melt the Bronze
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Solid Bronze Goes into the Furnace to Melt
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Solid Bronze Goes into the Furnace to Melt
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Lifting the Lid off the Furnace
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The Molten Bronze is Lifted Out of the Furnace in a Container Called a Crucible
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Molten Bronze Hoisted out of the Furnace
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Molten Bronze Hoisted out of the Furnace
![](http://s93876915.onlinehome.us/chris-reilly_dotorg_WP-2013/wordpress/wp-content/uploads/blog.157.jpeg)
Molten Bronze in the Crucible
![](http://s93876915.onlinehome.us/chris-reilly_dotorg_WP-2013/wordpress/wp-content/uploads/blog.158.jpeg)
Molten Bronze Poured from the Crucible into the Two-Part Sand Mold
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Molten Bronze Cools in the Two-Part Sand Mold: Weights are Placed on Top to Contain the Hydraulic Pressure Created in the Mold
![](http://s93876915.onlinehome.us/chris-reilly_dotorg_WP-2013/wordpress/wp-content/uploads/blog.160.jpeg)
After About 20 Minutes, the Bronze has Cooled Enough to be Released from the Two-Part Sand Mold
![](http://s93876915.onlinehome.us/chris-reilly_dotorg_WP-2013/wordpress/wp-content/uploads/blog.161.jpeg)
Bronze Casting Released from the Two-Part Sand Mold
![](http://s93876915.onlinehome.us/chris-reilly_dotorg_WP-2013/wordpress/wp-content/uploads/blog.162.jpeg)
The Final Product: A Cast Bronze Plaque