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The Sandcasting Journey

The sandcasting technique used in the manufacture of Casts architectural hardware is a venerated artisanal process. Through their journey, the collaboration pieces are left with pitting and pour marks to embody a physicality akin to handcrafted sculptures.

The subsequent tumbling of individual components to smooth and soften, allows a remnant of the process to remain in the finished product. The unique surface texture serves as a physical timestamp of the fabrication itself.

Discover how the Casts collection pieces are crafted.

  • Pattern & Moulds

    The sandcasting process begins with pattern making. The craftsman creates a replica of the object to be cast, a mould of the shape is then formed by tightly-packing sand around the replica piece. Once the replica is removed, a mould of the final piece remains in the sand.

  • Clamping

    Once the craftsman has created two identical moulds, they are clamped together to create a final mould that is ready for metal pouring.

  • Melting & Pouring

    The Casts pieces are crafted from solid Bronze and Aluminium. These raw materials must first be in a liquid-state to be moulded in a sandcasting process. The metals are melted in a furnace before the molten material is then poured into the cavity of the mould and left to harden and solidify.

  • Shakeout & Cleaning

    Once the molten metal solidifies the mould is rapidly vibrated in order to remove the sand from the casting. Any excess metal and residual sand is removed in the cleaning process and any rough edges are smoothed.

  • Polishing

    At the final stage, the casting will be lightly polished to provide a functional surface for its final application. Surface finishes of varying grades can be applied to add refinement and to balance the raw nature of the sandcasted pieces.

“OUR HOPE FOR CASTS IS TO CLARIFY THIS DISTILLATION OF GEOMETRIC FORM INTO A TACTILE FEELING OF THE SANDCASTING PROCESS. FINDING THAT BANDWIDTH AND BALANCE BETWEEN TACTILITY AND SOPHISTICATION HAS RESULTED IN SOMETHING THAT IS SOFT AND WARM TO THE TOUCH.”

– Aaron Roberts, Edition Office

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