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Overview. "Cold-Casting" is a term used to describe the process of mixing metal powder with a resin to create castings that give the appearance of solid metal. The metal cold-cast process (also known as "bonded bronze") is faster and much less expensive compared with foundry casting of molten metal (lost wax process.)
- 9 min
- Materials
- 3D Printing & Sanding
- Mold
- Mixing and Pouring The Mold
- Mixing and Pouring The Cold Cast
- Polishing and Final Work
Cold casting is especially forgiving if the part is mostly cosmetic. The resin used to bind the particles together can be just about anything. While I am using my favorite, Innovated Polymers IE-3075, practically anything will do. It has a fairly long cure time, but the two-part glaze coat from the hardware store works well for this application too...
The master parts I used for this casting were 3D printed. I used quite a few outside layers with very little infill. An important thing to note with any resin casting is that the silicone mold will pick up every detail. This is a curse and a blessing. If you invest the time now on finishing the part and getting close to the desired look and feel, y...
To make the mold I took the prepared 3D printed parts and laid them out in a likely configuration. For these parts the mold only has to be one sided. Even though the parts have an undercut, the silicone flexes easily enough that these have a single parting line. The flat surface that the 3D printer used to hold the parts onto the bed will be made b...
Mix and measure the silicone as per the manufacturer’s instruction. Make sure to mix the silicone as thoroughly as possible. Early on I tried mixing gently to avoid bubbles, but this resulted in a silicone that remained sticky forever. If you have a vacuum chamber, degass the silicone before pouring. If you are using a pressure chamber, cure the si...
Smooth-On and most sites recommend a 1:1 ratio of resin to powder by volume. Through personal experimentation I’ve found that as long as the resin is mixed exactly, practically the same part can be made with up to 20% error in the powder to resin ratio. Once you go past that, the part either doesn’t luster properly or is too brittle. This is great ...
After demolding the part is ready for finishing. For this part it was decided that it would be significantly easier to drill the holes after the part was removed from the mold. The other option would be to have a pin in the mold or a two part mold. This would have required significantly more time to finish. The part will come out of the mold with n...
There are three methods that we typically recommend for creating cold cast bronze pieces [Figure 1]: solid casting, slush casting, and bronze dusting. If you’re working with Polytek ® rubber mold materials, keep this in mind: both polyurethane rubber molds and silicone rubber molds can be used for the first two processes, while the last one ...
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Dec 20, 2023 · In this blog post, we explore the nature, characteristics, and what makes cold cast bronze special in the creation of bronze statues. What is Cold Cast Bronze? Cold cast bronze is a material made from bronze powder mixed with resin, used for making sculptures and other artistic creations.
Bronze resin sculpture, also known as “cold cast bronze” or bonded bronze, is created by blending bronze powder with epoxy, polyester, or another resin and pouring the mixture into a reusable rubber mold. The process doesn’t include the “long wax” process which is a significant step in the hot cast bronze process.
So, how does Metal Cold Casting work? It involves using the same metals like Bronze, Aluminium, Copper, or Brass but in a different form. These metals are meticulously ground into a fine powder and then blended with a casting medium. This metal-infused mixture is subsequently poured or carefully painted into a suitable mold.
Oct 15, 2019 · In this tutorial we explain the "dusting" technique of cold-casting. This process entails pouring copper powder into a soft silicone mold (in this case a soft Gel-10 mold), pouring it back out,...
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