Making the Molds

Since the "original" wax carving will not withstand the heat and pressure of making a rubber production mold, pewter "prototypes" are made. The wax original is placed in white liquid rubber to which a hardener has been added. After curing, the original is removed from the mold, leaving a cavity. A "gate" or channel, through which molten pewter will flow, is cut in the rubber. Small vents are also cut to allow air to escape, aiding the flow of molten pewter into the cavities. The resulting pewter castings are finished to perfection, creating the masters or "prototypes" used in making the mold.

The casting molds are made from a synthetic rubber that can withstand, for a limited time, the heat of molten pewter. To make the molds, prototypes are placed between uncured rubber discs contained in a steel form. The mold is placed in a vulcanizer and subjected to heat and pressure, causing the rubber to become putty-like and flow around the prototypes. After an hour, the rubber is cured or set. Gates and vents are hand-cut in this mold.

The Casting Process

In preparation for casting, the mold is lubricated with a dusting of talc and lowered into the casting bin. Molten pewter is poured through the funnel and into the center of the mold. Centrifugal force propels the molten pewter into the cavities. Perfect castings are set aside for finishing and the balance of the pewter is recycled back into the melting pot for other castings.

Finishing Cast Pieces

After casting, excess metal, or "flash" from around the edge of each pewter piece is removed using snips or a sharp knife. The edges are then smoothed on a sanding belt and a finishing wheel.

Most cast pieces are buffed on small, vertically spinning wheels of various materials to soften their edges. The satin finish on most pieces is achieved by using wire wheels in the final polishing process.