About This Program
Metal casting is one of humanity's oldest manufacturing techniques - and one of the most exciting. Students design a shape in foam, bury it in sand, and pour molten aluminum to create a permanent metal object.
Using the lost foam technique, students watch their foam pattern vaporize as liquid metal takes its place. It's industrial-scale manufacturing made accessible and safe for older students.
What Students Learn
- Lost foam casting process
- Melting and pouring metal safely
- Pattern design and gating
- Sand casting fundamentals
- Metal finishing techniques
- Industrial manufacturing concepts
Session Format
- Safety briefing and overview (30 min)
- Design and carve foam patterns (60 min)
- Prepare sand molds (30 min)
- Melt and pour aluminum (60 min)
- Cool down, extract, and finish (60 min)
