After learning the process of casting metals like brass and aluminium, the aim of this project was to create a product using this magnificent craft. Metal casting is a technique in which liquid metal is poured into a mould which contains a hollow cavity of the desired shape and then allowing it to cool and solidify is the process of sand casting.

I first worked on my design and later sketched the same on a wooden piece which was going to become my mould for the sand casting process. I used Red Sal and carved the entire wood in the desired shape. The mould was then placed  in a sand box and then removed to form a void of the pattern. Molten metal was poured into the sand box for the metal to take the shape of the void created. Two castings of the same mould was done for it to form one piece by joining the two casted pieces later on. Gas welding was done in order to join the two pieces together. The casted pieces were filed and cleaned. Buffing was done and the product was give a glossy finish. 

My product is inspired from 
ancient brass door knockers

Design sketched on the wooden pieces

Mould carved using hand carving tools

Creating a void using the mould

Pouring molten aluminium in the sand box

Unfinished aluminium pieces

Finished piece after polish and buffing

I chose to cast my door knocker in aluminium since I was working on a contemporary design and also, brass door knockers are really heavy. 

Aluminium is light weight, economical and appealing when given the right finish. The design is contemporary and intricate. The roots of the design are from the ancient period, beautiful and magnificent.