Tag Archives: SCUL 349

SCUL 349 – Styrofoam Sculpture Part II

The finished styrofoam sculpture held together with toothpicks and masking tape for texture. Covered in a red oxide that strengthens the entire sculpture.

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The sculpture is placed into the sand bucket and filled, topped off with a cone made from the same mix as the investment casting, as a funnel for the aluminium.

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The piece after cooling from the pouring.

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At this point I was wondering what was flaking off the sculpture when I suddenly realised it was the masking tape.

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With the masking tape removed the sculpture is left with a crinkled-like texture and some amazing colouring. To keep this colouring I left the piece to cool naturally instead of cleaning the metal with cold water.

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SCuUL 349 – Styrofoam Sculpture

The next sculpture will be made into aluminium but to get the original shape I am using styrofoam. For this piece I was inspired by Skyrim’s Dragon Priest mask. To begin with I created a cast of a face using plaster wrap and drew the design onto the mask to see how it would fit together if the finished piece would be worn.

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After this I drew the different pieces onto the styrofoam, cut them out, and filed them down.20140921_145705

Finally I stuck the pieces together with toothpicks as they will burn away when the aluminium is poured. I am considered using masking tape to hold the pieces together properly as I have see the outcome of this texture on a different piece and quite like it.

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SCUL 349 – Creating The Mould For Aluminium Casting

1. Mold the clay around the item for support and screw together a box around the item and clay

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2. Fill the container with a mixture of sand and…

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3. Insert… to compact the sand

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4. Once everything feels more solid slowly unscrew the box, being sure to fill any parts that feel soft.

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4. Remove the clay and object from the mould

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5. If anything is stuck inside the mould carve gently and careful around it until it is removed safely

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SCUL 349 – Investment Casting

Investment Casting:

  • Pouring a slurry of plaster and sand around a wax pattern, attached wax gating structure
  • Pattern held in place until plaster mix has chemically set
  • Mold is placed in burnout furnace, slowly heated, internal temperature 1000 degrees
  • High heat melts out most wax, burns away any carbon residue
  • An hour per inch in diameter
  • Mold is removed, packed in a sand pit
  • Metal/ Glass poured into mild
  • Requires most fuel, takes the longest to prepare, and is by far the most polluting
  • Process works with bronze, aluminium, and glass

My Process:

1. Flatten out a piece of clay to serve as a base and place object on the base.

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2. Build up the clay around the sides to created the clay structure and shape the relief. Remember to keep the section you want in your relief exposed.

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3. Build a secure wooden structure around the clay structure.

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4. Pour in the mixture of water, plaster, and sand. Leave to set.  (1/2 water, 1/4 plaster, then mix, 1/4 sand, mix)

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5. Remove the wooden structure and carve out the clay structure and object.

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6. Carve into the set plaster mix if more detail is required or if you want to remove detail.

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7. Remember to throw away anything that has touched raw meat correctly, and clean your area appropriately.

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