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Lesson Context
A KS3 introduction to green sand casting
Resources Needed
Computer and printer with 2-D drawing and design software.
3mm and 6mm MDF
Machine fret saw or scroll saw
Green sand casting materials and equipment
Teacher Preparation
Organise small moulding flasks, oil-bound sand, parting sand, braze large washers into end slot of 3X12 woodscrews to make rapping pins, cut short lengths of 10-12mm ms rod to make rapping irons, 25mm dowel to ram up and 25 mm thin gauge tube to cut runner and riser.
Have 3mm and 6mm MDF pre-cut into varying width strips
Project Brief
A local Garden Centre wishes to introduce a range of cast aluminium house numbers. The plaquettes must not be greater than 10000 square millimetres in area and are to be priced according to the number of digits. Small motifs may added and these are priced as a single digit.
Design and Manufacture
Investigate similar products and choose suitable shapes, fonts and motifs.
Design a prototype plaquette using a computer.
Print-out the final design and glue on to 3mm MDF.
Cut out the shape using an electric scroll saw or machine fret saw.
Glue the cut-outs on to 6mm MDF and use filler to form fillets where needed.
Sand smooth, paint and cast using green sand casting techniques.
Expected Outcomes
A range of cast aluminium plaquettes
