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From the forge

How we pour

A few pieces on the counter come off our own bench, poured by hand in small batches. Here’s how a pour goes, start to finish.

Pouring molten metal into an open mold
  1. Blue resin patterns set on a tree, ready for casting

    Step 1 of 6

    Pattern

    Every piece starts as a pattern. We print each design in castable resin and set the patterns on a tree, so one pour fills several pieces.

  2. Copper grain in a dish on a digital scale

    Step 2 of 6

    Weigh

    We weigh the metal grain for each flask, so every pour has just enough.

  3. Steel flasks heating in the kiln

    Step 3 of 6

    Burn out

    The tree goes into a steel flask filled with investment, a fine plaster. The kiln burns the resin away and leaves a hollow mold in the shape of each piece.

    • Lifting a flask out of the glowing kiln with tongs
    • A hot flask set on the casting table
  4. Metal glowing in the crucible, seen from above

    Step 4 of 6

    Melt

    The grain goes into the crucible and heats until it glows.

    • Pouring copper grain into the furnace
    • Stirring the melt
  5. Lifting the glowing crucible from the furnace

    Step 5 of 6

    Pour

    We lift the crucible with tongs and pour into the hot flask. Tokens pour straight into open molds.

    • Pouring molten metal into an open mold
    • Our caster, in a respirator, lifting the crucible
    • A fresh pour still glowing in its molds
  6. A finished copper eagle token in hand

    Step 6 of 6

    Finish

    Once it cools, each piece is cleaned up, weighed, and stamped.

    • Fresh-cast copper tokens in a palm
    • A copper cross propped on a stone

On the counter now

Poured here

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