Step 2

Special wax is poured into the impression and allowed to cool.

Step 3

The wax cast is removed from the impression. Then it is cleaned and carved into shape. The back is flattened and the inscription is written into the wax. This will be the pattern for the metal Pet-Paw.

Step 4

The wax pattern is then molded using the greensand method. The example in the photo is a mold for a cat head gate latch. The 4 piece iron pattern is on the table in the foreground. After the greensand has been packed around the iron pattern, the casting flask (wooden box) is opened and the iron pattern is removed. Then the two halves of the casting flask are put back together and clamped tight.

Step 5

The foundry is fired up! A crucible full of brass, bronze, or copper takes about 1 hour in the foundry before it can be poured. The temperature will reach about 1800°F (2000°F for copper).

Step 6

The molten metal is poured into the sand mold very quickly.

Step 7

After the metal has cooled sufficiently, the flask is opened. Sand is cleaned away from the metal. The metal casts are cut away from the excess metal gating system, then they are ground, sanded, and polished.