Metal Casting - Maker Lab Kids

👥Ages 14+

⏱️4 hours

👨‍👩‍👧‍👦Max 8 students

🏆Students keep their castings!

Foundry furnace with glowing molten aluminum

Pour glowing molten metal and create permanent aluminum objects!

Real Foundry Work - Industrial Manufacturing Techniques

What Students Will Do

Design in Foam - Carve or shape a pattern from styrofoam
Prepare the Mold - Pack the pattern in sand with proper gating
Watch the Pour - See 1,200°F molten aluminum flow into the mold
See the Magic - Watch foam vaporize as metal takes its place
Cool & Extract - Break out the mold and reveal the casting
Finish & Polish - File, sand, and polish to final form

What Students Will Learn

Lost Foam Casting

An industrial technique where foam patterns are vaporized by molten metal.

Metallurgy Basics

How metals melt, flow, solidify, and what affects casting quality.

Pattern Design

How to design shapes that cast well - draft angles, gating, vents.

Industrial Manufacturing

How real factories use casting to make engine parts, tools, and more.

Safety Is Critical

Age Requirement - Ages 14+ only - this is advanced metalworking
Full Safety Gear - Face shields, leather aprons, heat-resistant gloves
Instructor Controls Pour - Students observe pour, assist with prep
Clear Safety Zones - Designated areas during hot metal operations
Outdoor or Ventilated Space - Fumes require open-air environment
Perfect Safety Record - Years of workshops without incidents

What's Included

Propane foundry furnace
Casting sand
Foam for patterns
Aluminum ingots
Full safety gear
Finishing tools

Workshop Details

Format: One-time workshop with multiple phases
Duration: 4 hours (includes cooling time)
Group Size: Maximum 8 students
Space Needed: Outdoor area or well-ventilated workshop
Equipment: All included - furnace, sand, foam, safety gear
Takeaway: Students keep their finished castings!

Perfect For

High School Programs - Advanced STEM elective
Career Tech Education - Industrial arts connection
Summer Intensives - Half-day advanced workshop
Maker Spaces - Add metalworking capability
Scout Groups - Advanced metalworking badge

Why This Workshop Is Special

Real Industrial Process - Same technique used in manufacturing
Permanent Creation - Aluminum objects last forever
Rare Opportunity - Few places offer this to students
Career Connection - Foundry work is a real profession
Unforgettable Experience - Pouring molten metal is unforgettable

Metal Casting in Action

Foundry furnace glowing

Cast aluminum skull

Finished casting