The Casting Process

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Our workshop is home to a propane-fed smelter that heats pewter to 550° Fahrenheit, two centrifugal casters, a vibratory tumbler for polishing, and some 2,000 molds.

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The work day begins with starting the smelter and turning equipment on, checking safety gear, and getting molds for the first shift of casting set out.

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Molds are dusted in Talc powder as needed and placed into the centrifuges, which spin the circular mold around and around. When molten pewter is poured in, the centrifugal force feeds pewter throughout the entire cavity of the mold. As the pewter begins to rapidly cool, air pockets form and are subsequently forced out, leaving behind a fully solid metal cast.

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Once cool enough to handle, the pewter casts are removed and examined for quality.

 

Those that pass muster get sent to the next work station for finishing, where we remove any rough seams or spurs, before polishing begins.

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Final Touches: Color & Gem-Setting

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Many of our designs are enhanced with professional grade epoxy resin for a splash of color and personality, or accented by the addition of real Austrian Crystals and durable plastic jewels. 

 

Our epoxy resin choices come in a variety of 14 available colors, ranging from flat gloss to dazzling glitter blends.

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Charms ready to be enameled are cleaned of any residual contaminants, then arranged on a portable sheet. Epoxy resin and hardener are measured out by weight, then mixed and loaded into our pneumatic dispenser (a fancy phrase for air-powered!). Once the entire tray is finished being filled with color, or stoneset, it is moved into a dedicated drying room where it sits and cures at 72° Fahrenheit, for 2-3 days.

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