This page documents the steps involved in casting a plaque.

I start off by scanning the logo then tracing it out with vector based software.

The vectors are then used to create a CAD file. The CAM software uses the CAD file to make machine codes for the CNC machine.

My homemade CNC machine cuts the part out of foam.

You can see a video of this on the CNC page.

This is the front view; the foam is coated with joint compound. The compound is used to preserve the finish and prevent a sandy texture.

The bottom with the sprues and some straws. I melt a hole through the sprues to help the molten metal get down and escaping gas get out. No compound on the back, it's not going to be seen and I believe it also helps the escaping gas.

The foam buried in sand except for the very top of the sprue.

Pouring the molten aluminum.

Pulling the piece out of the sand about 15 mins after the pour. Still has the compound on it but it's no longer foam.

Most of the compound comes off pretty easy after quenching the hot piece in water.

This was all just a test to see if the sprue and runners worked. This piece had some machining flaws but the casting worked great. Here you can see a horizontal line from a depth malfunction in the machining process. After seeing this cast in aluminum, I've decided to make a few changes and then cast it in brass.

See the finished plaque on the Castings page