Skills Used
In May 2024, I had the honor of participating in Segal Design Center’s Annual Iron Pour led by Professors David Gatchell and Matthew Cummins. I learned to manufacture using a centuries-old process of smelting and casting molten iron.
CAD Modeling, Mold Design, Smelting & Casting, Power Tools, Metal Finishing, Patination, Safety
Step 1: Create sketch of initial idea.
This is a modified Dharmachakra wheel, which represents the harmony of life in Buddhism. My version has Platonic solids embedded in the design, as the Greek philosophers believed these shapes to be the fundamental elements of all life. My piece is a fusion of these Eastern and Western ideologies and also looks badass.
The Iron Pour
Step 4: Open and clean sand molds.
Step 6: Break down scrap iron.
Step 7: Portion out iron and coke.
Step 8: Assemble furnace.
Step 9: Melt iron.
Dodecahedron
Step 3: Create CAD Model of mold to be made into sand mold.
Step 13. Cut away excess iron (mold geometry).
Step 2: Create CAD Model of part.
Tetrahedron
Step 12. Break open the molds and revel in the glory.
Octahedron
Step 5: Bind molds and pour cups
Step 10: Get your safety gear on!
Step 16. Soak the piece in a patina to finish.
Step 11. Pour the molten iron into the molds.
Step 14. Use a dremel and sandblaster to smooth the cast.
Step 15. Angle grind the faces to a smooth polish.
