Study material

This material gives you an overview of the casting process and the concepts you encounter at a foundry. Use it as reference while you learn the trade in practice.

The casting process in brief

• 01Shape: made according to a model and gives the workpiece its form
• 02Melting: the metal is heated until it is liquid
• 03Casting: the metal is poured or pressed into the mould
• 04Solidification: the metal stiffens and takes the shape of the mould
• 05Post-processing: the piece is cleaned, ground, and checked

Form types

Sand moulds are pressed around a model and are suitable for complex pieces; they are broken to get the piece out. Permanent moulds are reusable and suitable for many identical pieces. Pressure casting presses the mass in under high pressure for uniform results.

The metals

You work with iron, steel and other metals. The choice depends on what the workpiece needs to do: strength, weight or resistance to specific loads.

Safety you must always remember

• 01Keep molds and tools dry near melting
• 02Use heat-resistant clothing and the right personal protective equipment
• 03Use lifting equipment correctly for heavy items

How you practice best

Start by understanding each step individually, then build up the whole. Be careful with pattern-making, because errors here cannot be corrected once the metal is poured. Take quality control seriously from the start.

“The foundry trade rewards planning. It is what you do before the melt that determines what you get out of the mould.”