TE 390.1 Casting Techniques; FALL 2011
Location: 430F
Monday 2:00 pm – 6:00 pm
Instructors: Andrew Wilhelm, Betsy Alwin
contacts: sngldbltrpl@hotmail.com / betsyalwin@hotmail.com
Class Overview
The focus of our projects will be the processes and techniques of metal casting. Though we will concentrate primarily on casting bronze, the means by which we realize the finished projects will introduce processes of modeling, mold making and finishing that will carry over into your future studio practice. Our discussion will involve the history of such practices and their place in contemporary art.
The techniques and terminology of casting bronze have not changed much since the alloy was discovered and developed nearly 6000 years ago. The method of “cire perdue” (lost wax) is an ancient method developed in ancient Egypt. Bronze was the chief cast material by which tools and weapons were manufactured and developed during the Bronze Age (3,500 – 1,500 B.C.) Bronze became popular for monuments and statuary, a more versatile and durable alternative to stone carving. As a modern and contemporary art material, bronze has been traditionally used to cast some very untraditional forms and objects.
We will cover several processes of the lost wax technique, concentrating on proper molding techniques, investment, casting and finishing techniques. You will be encouraged to explore new forms and ideas in casting, considering both the possibilities and limits of the material.
Course Objectives:
- Learn and develop mold making techniques
- Practice and understand methods of casting metal: proper use of materials, equipment, and safety.
- Explore and discuss historical and contemporary examples.
- Realize two finished projects in metal.
Required Materials:
Most of the materials you will need for this class will be provided or will be available for purchase from the Sculpture shop.
- All casting wax will be provided as well as venting / gate wax.
- If you require rubber for molds you may purchase rubber by weight from the shop. Be sure to weigh the material used and pay for it immediately.
- You will be charged by the weight of your bronzes and the size of the flask used. Please consider this when planning your projects. If you decide not to keep your bronze you must still pay a fee for the casting materials.
You are required to purchase and keep on hand the following:
- Respirator with filters rated for particulates-(P100).
- Leather boots or shoes for casting.
These two items are for safety. Fully familiarize yourself with the MSDS provided in the shop. The foundry and investment materials contain silica sand. Silica dust irritates the respiratory system and with exposure can cause an illness called silicosis. While working with these materials or in this area you MUST wear your respirator. If you have asthma or other respiratory problems that limit your use of a respirator, please talk with one of the instructors immediately.
Student responsibilities and grading:
Your grade will be assessed in the following manner:
- 30% Class participation (attendance, participation in discussions and team pours)
- 25% First assignment (the amount of time, effort and attention spent / quality of finished project, timely completion)
- 45% Second project (the amount of time, effort and attention spent / use of demonstrated mold-making skills, quality of finished project, timely completion)
We cover a large amount of important information quickly in demonstrations and discussions. You are responsible for any information or demonstrations you miss due to illness or emergency.
Please refer to Cooper Union’s attendance policy. More than two absences will result in one lower letter grade. Three absences may result in mandatory withdrawal of the class. Lateness will not be tolerated. Two late arrivals to class will result in one absence, and will result in one lower letter grade. If you must leave the class early for any reason during the semester, please inform the instructors in advance of the class. Leaving the class early without being excused by the professors in advance will count as an absence.
Because the pours and investments require teamwork, attendance is essential. Casting is a time intensive process. The scheduling of investments and pours require steadfast deadlines for mold making and waxwork. It is common to underestimate the time needed for the process of completing a bronze work. You will make mistakes along the way; this is normal in the learning process. PLAN YOUR TIME WISELY.
Expect to spend at least six hours a week outside of class for your projects.
Late projects policy: All students in the class are expected to participate in critique whether or not they have completed their own assignments on time.
Each day that a project is late the letter grade will be dropped by one third. Students must make an appointment with the instructors to evaluate late projects.
Please speak with the instructors in advance if there are any extenuating circumstances regarding late projects.
GRADING SCALE:
A range: Outstanding performance: commitment to the quality and development of concepts and of work completed, timely completion of all assignments, significant dedication of work outside class time (good balance of time spent proportional to the level of project), highly engaged class participation.
B range: Above average performance: Good quality of work completed, timely completion of assignments, consistent amount of hours outside class time spent to finish project, active class participation.
C range: Average performance: completing all assignments, some hours outside of class time spent on projects, requisite attendance and participation.
D range: Below average performance: completing assignments excessively late and/or minor commitment to the quality of work completed, minor participation and/or excessive lateness, work time spent outside of class not proportional to the scale of project.
F range: Failure: Incomplete projects and/or excessive lateness and/or absences, little commitment to work done outside of class.
Note on finished projects:
Though ambitious projects are welcome, you will not be graded on the scale of your projects per se. You will be graded on your ability to finish what you have begun, management of class time and outside class time, the development of your concepts and ideas through the material, the level and quality of finish you bring to your projects, and the presentation of finished projects in critique.
Course Outline: Subject to change
September 12, week one * there will be a $25 charge for withdrawal after the 18th.
Introduction.
Slide show.
Foundry orientation.
Demonstration: Wax modeling. Other model materials. Direct sprueing
Investing a centrifuge flask. First assignment: Two Week Project
September 19, Week two
Tour Modern Art Foundry, Queens. MEET AT MAF 9:45 AM
Meet with Andy or Betsy during week for help with projects.
Work on wax pieces, direct sprue systems. Purchase respirators.
September 26, week three
Waxes due. Group investment session. Have respirators for class. Wear work clothes.
Load investments into kiln. Prepare metal for next week. Burn-out over weekend.
October 3, Week four
Pour First project. Devest after pouring. De-gate and recycle cups and sprues. CLEAN UP! Begin working on 2nd project Idea/Drawings
October 10, Week five
Mold-Making techniques. Casting wax and other materials.
2nd project ideas.
October 17: Week six
Bronze finishing techniques.
Work on molds for 2nd project.
October 24, Week seven
Critique 2nd project. Begin ideas for final project
Sand casting demonstration.
October 31: Week eight
Final project ideas. Indirect sprue systems.
November 7, Week nine
Body casting techniques
Work on final projects
November 14, Week ten
Work on sprue systems
Invest by Thursday night; burn-out over the weekend
November 21st, Week eleven
POUR-Cast final projects. Bring all safety equipment and proper work clothing to class!
Nov. 24th-27th-HAPPY THANKSGIVING! THE SHOP WILL BE CLOSED OVER THE WEEKEND. PLAN ACCORDINGLY
November 28th , Week twelve
Demonstration: Alternatives to toxic methods of casting: FGR and Aquaresin™
Chasing / finishing / welding / technical
December 5th, Week thirteen
Demonstration: Casting techniques in the studio (when you don’t have a foundry)
Work on final project
December 12th, Week fourteen
Individual review of projects / work day
December 19st: FINAL CRITIQUE. Location TBA.
