Foundry Pattern Making Is Considered To Be a Black Art – But we have a book that will help to dispel the myth.
It goes with out saying, if you want to cast something, generally, the first thing you’ll need to do is to create a pattern –
Foundry Patterns Can Be Made From:
- Timber – (Special fine grain soft timbers)
- Resin – (2-part)
- Polyurethane – (Part A&B plus some additives)
- Metal – Zinc – Aluminium – Bronze
- Plastic – (Machined or Moulded)
- Styrene Foam – (Hand cut – Router cut – Steam Blown – as commercial foundries do)
It really depends on the intended purpose, and how long the pattern will be in use – sometimes a one time use pattern is required – other times, you might want to make numerous moulds with the pattern.
Want To learn How To Unravel The Mysteries That Surround The Making Of Timber Foundry Patterns?
Many people don’t realize that Hobby Foundry Patterns can be made with everyday woodworking tools…
Don’t believe it. Well, that’s what the old foundry pattern masters basically had to rely on.
Often we are told to think outside the square to solve problems, or to find solutions to all kinds of things, I can tell you that the old-time pattern makers were certainly thinking outside of the square long before the “term” became fashionable.
Pattern making enables the conversion from a basic idea or sketch on paper, into a solid pattern reality, all it takes is some thought and the application of tried & true basic pattern making skills.
The methods are simple for the home hobby worker to put into practice, but the amazing thing about the art of traditional pattern making is that you don’t need expensive 3D Cad Cam software programs to design & build good patterns for your hobby foundry.
But don’t get me wrong, I am not knocking new technology, for it is an exciting period we live in right now.
But you would have to admit, the real fun and personal reward is applying the traditional skills to make nice quality patterns using your hands and a few basic wood working tools.
The average hobby worker most likely wont know how to use complex software programs, let alone afford to buy them, but he/she would feel right at home with a mallet and a couple of chisels.
To design good patterns in your home workshop, you will need a basic set up; A sheet of drawing paper, a set of drafting or drawing instruments, a T square, drawing board or table surface, pencils, and your off to the races.
Some people have already adopted CAD drafting and low cost 3D Printers, but they are the exception in the hobby foundry game at the moment.
The Simple – Low Cost Way To Success For The Beginner.
Here is an opportunity for you to obtain ready access to a ton of practical pattern making knowledge outlining how to use common woodwork tools to make patterns using nothing more than a piece of wood, a few chisels, some glue & perhaps a simple woodwork lathe.
Improve Your Skills – Learn The Techniques.
There are certain processes you must go through to produce foundry patterns, you may have to learn how to think and visualise things in reverse, especially when you need to make a core box, you also need to know how to apply the rules of shrinkage and pattern draft.
This ebook will explain all of those things in a way that you will understand, while reading, you’ll probably have one of those, Ah ha moments, and things will begin to fall into place, the ideas are sure to flow… you’ll be on track.
Above: Cast Aluminium Oil Filler Cap For 1949 MG TC.
A replica RTV master plug pattern was taken from an original MG TC oil cap – The production patterns were then cast with diluted auto body bog – the lower part opf the pattern were machined with taper (draft) from aluminium – Note the way the in-gates are arranged in the picture on the left, and then note the arrangement of cross runner in the middle picture – Can you understand how the metal is fed into the mould cavity? There is also a small recess in the runner to locate the down (Pouring) sprue – Risers (feeders) can be placed on the in-gates.
The patterns produced excellent sand moulds and castings as shown on the right (Above) – The details in the ebook package explain the process of making exact replica patterns – which can be applied to so many things.
Below, three simple diagrams about sand moulding….a flat face washer pattern… a very simple foundry project, but it still has its little problems… the outer curved profile will allow excellent withdrawal from the sand… the inner tapered core may need a separate sand core, or it may be possible to ram the mould and have the green sand form the inner sand core…there are two very simple tricks to apply when forming a green sand core so that the core does not break off when withdrawing the cope or top part of the flask, and they are explained in the ebook and course.
The diagram above shows the sand mould is complete, the pattern has been withdrawn, the sprue and riser are in place, the only thing left to do is to melt and pour the metal.
You may not want to make the things explained in the pattern ebook, but the details and explanations will certainly help you to understand what the black art of pattern making is all about, and how to apply the techniques to your own projects.
This book would sit well in your hobby foundry library.
The book is a gem, even though the technology hails back to the early part of the last century, pre 1911 to be exact, you might think that’s a bit old hat, but it’s not, the methods & techniques outlined were commonly employed in the days when everything was done by hand…
Just like you currently do in your hobby foundry.
To be sure, I was pretty amazed at the things I learnt while compiling & editing the book, it throws a whole new light on the unique lost methods of making foundry patterns, even complicated pattern shapes, and still be able to withdraw them from the moulding sand.
As an example, the book begins with a basic pattern shape.
These are just a small sample of things you’ll learn, the book also outlines several cool tricks to use when you may not have a complete pattern, and also methods you can employ using multiple flasks to get around awkward pattern shapes.
There’s a complete section about using sweep mould making methods when you can’t make a full pattern, sweeps are mainly used to create inner and outer shapes for bells, but they are applicable to many other things.
Ever heard of a follow board? Do you know what a follow board is?
No, well, they allow unusual or odd shaped patterns to be moulded and cast without difficulty, which I’m sure you’ll want to know about.
This book will open up many new possibilities when creating your patterns, feel free to adapt many of the principles and methods explained in the ebook to your own work. Even if you only get to use half of the ideas outlined.
Your pattern making and foundry skills will certainly take a leap forward.
The foundry techniques described in the Pattern Making Workshop Practice book for green sand prove that green sand is still considered to be a versatile & highly effective moulding medium.
There is also a section on the best types of pattern timbers to use, and which timber to stay clear of when choosing the right timber to make your patterns.
Pattern Making Workshop Practice will provide more than just the basics of pattern making, it will be a valuable reference book for your foundry library for many years to come.
The modern foundry pattern shop employs many new materials, techniques and methods to produce production patterns, below we have a short video to show you rigid polyurethane patterns being poured.
Pouring Quick Setting Polyurethane Patterns – EPS Pattern Engineering-Beechworth-Australia.
There’s more than sixty seven pages of learning, including more than eighty detailed cross section drawings. You will understand & really enjoy the reading & learning.
You may think that making timber patterns is time consuming, difficult, and perhaps not worth the effort, you may even prefer to use foam patterns. The lost foam casting technique certainly has it's place in the commercial and hobby foundry, but there are problems associated with lost foam. And if you are experiencing problems with lost foam, it could be due to not having a proper understanding of how traditional timber patterns are made, in fact, if you put the question to a skilled pattern maker i.e,"Should I use foam when starting out" he would most likely tell you: "That it's probably not a good idea to use the lost foam method as a novice, that is, not until you fully understand the basics of making timber patterns, there are so many variables with the lost foam casting method which will produce a bad casting which you certainly won't experience when using a timber pattern rammed up in green sand".
If you are a steam buff you will love the section on how to make a pattern & core box to cast a brass steam whistle.
Read what other hobby foundry workers have to say about the pattern making ebook.
Testimonial 1.
I really enjoyed reading the 'Pattern Making Workshop Practice' ebook. As a newbie I'd always assumed that pattern making was basically a "no-brainer" affair. Naively I used to think that patterns were fairly simple and done in two boxes. Nothing could've been further from the truth! It now absolutely amazes me what can be accomplished with complex pattern making!
Thanks to your insightful ebook I now know how to deduce what pattern configuration to use basically from any casting work that needs doing! Compound flasks, soldiers, pattern sweeping, balance cores etc, are all terms and techniques that I now understand. I look forward to applying these principles to my own metal casting. Thanks again for a wonderful book and the preface in the book 'Knowledge is Power' certainly is an appropriate adage as my pattern making knowledge has been improved ten-fold.
Thank you Colin,
Testimonial 2.
This book provides a good overview to pattern making within the context of the foundry. The principles still apply today and whilst it would appear to be aimed at the novice, there is much for the experienced. Being well illustrated with cross sectional line drawings, the spirit of the book appears to be that virtually any shape is castable. This is an easy to read book which I think will be a useful addition to the bookshelf of anyone interested in metal casting. Although some of the techniques may be dated, it contains much information which provides inspiration and be a source of ideas and work around for solving casting problems.
Purchase The Pattern Making Workshop Practice Book Today.
Only $29.97US
A Sound Investment In Your Foundry Pattern Knowledge.
It’s potentially worth three times the price for the amount of information it provides.
After your purchase, please wait to be re-directed to the download page – it may take several seconds. If you encounter problems, please don’t panic, contact us for assistance.