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Traditional Metalcasting: The Art of Sand Mold Making

Why This Matters:
• Rural Industry: Supports 30% of cookware production in developing regions
• Material Efficiency: 98% of molding sand can be recycled
• Cultural Preservation: Maintains 500+ year old foundry techniques

Mold Making Process:

1.
Pattern Preparation

Wooden/master patterns coated with parting compound
Registration pins aligned for two-part molds
2.
Sand Compaction

Layer composition:
• 80% silica sand (50-70 AFS grain fineness)
• 12% bentonite clay
• 8% water
Rammer tools achieve 85-90% density
3.
Mold Finishing

Vent holes poked every 3cm²
Charcoal dust coating prevents metal penetration
Pouring cup/gate system carved at 15° angle
Technical Specifications:
• Mold Strength: 10-15 N/cm² (hand test)
• Drying Time: 24-48 hours natural drying
• Casting Tolerance: ±1.5mm for small cookware
• Mold Life: Single-use (sand recycled)

Quality Indicators:
• Uniform gray color indicates proper moisture
• No visible cracks after pattern removal
• Smooth runner system with gradual transitions

Safety Considerations:
• Silica dust protection (N95 masks required)
• 2m minimum clearance for molten metal handling
• Sand temperature monitoring (＜40°C for handling)

Production Data:
• Daily Output: 15-20 molds per artisan
• Aluminum Yield: 85-90% from melt to finished pot
• Pattern Lifespan: 200-300 castings before wear

These videos document the disappearing craft of manual sand molding, where artisans' tactile knowledge produces cookware that outperforms many factory-made alternatives in heat distribution and durability.