We, at John Williams & Company, offer a bespoke lead casting service. We use traditional moulded sand techniques to create seamless lead plaques and decorative features. If you would like a quotation for a lead casting or just some advice please contact us.
Method of Sand Casting
A template is made in the exact form as the required finished lead feature. Templates can be made from any material so long as it is relatively smooth. Sand moulds will take the shape of even the finest of details so if materials such as natural timber are used the mould is likely to also incorporate the grain of the wood in the casting process.
The template is dusted with parting powder to ensure the sand and template separate easily and then framed to form the casting box. Oil bonded moulding sand is then applied over the template. The first layer of this is hand sieved to ensure that all of the fine details of the template are well formed. The remainder of the sand required to fill the casting box can be added simply by hand without the need for a sieve.
Once the casting box is full with sand it must be tightly compressed in order to both take the shape of the template and form a solid bed of sand suitable for pouring lead into. If the sand is not compressed sufficiently it could collapse around the template when removed or fail to form correctly on more intricate templates. The compacted sand is then struck off to form a flush, level face of sand. If the sand is not level the mould could deform once the box is flipped over for pouring.
The completed lead items can now be cleaned up and finished as necessary. This technique can be used to make items from lead hoppers to decorative plaques and vents. If you would like to get a quotation for a lead casting or need some advice please contact us.