HIghlights from our class this semester

Kristi Cavataro's 4 foot extruded spoon was cast using a "green" method of casting:  Green sand casting.  It's a bit like making an inverse sand castle.  It usually involves a two-part box (called a flask) that is a little bigger than the pattern being cast.  Then damp sand is rammed up around the pattern very tight and compact, getting all the detail and form.  Green sand casting traditionally works well for simple patterns because the rammed sand must be able to easily separate from the form.  After ramming the sand around the pattern, you must be able to remove the pattern, leaving a cavity that will be filled with the molten metal.  For this reason, intricate or complex objects are not ideal for green sand casting.  In this case, Kristi made a special three-part wooden flask because she wanted the filigree detail of the top of the spoon.  She sculpted her original pattern from reinforced cement and a spoon.  She plans on polishing the finished aluminum to a mirror finish.  Fantastic!