Feature Article That’s a Winner!
Creating a Casting to Honor the Best in Casting by Erich Knoespel, Artcast, Inc.
T
he design for the ICI casting conference medallion started with a phone call. The Investment
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Casting Institute wanted to update the casting contest award plaques and were interested in a custom medallion that would accurately and elegantly represent the investment casting industry. We were given fairly free reign on the design, the required elements were the ICI logo, “Investment Casting Institute”, and “Casting Contest Winner”. We had just started to experiment
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Pacific Kiln & Insulation Co. Inc.
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Pacific Kiln & Insulation Co. Inc.
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with 3D technologies as we just passed our fiftieth year. While going through the archives, we had come across some early photographs from the early 1970s of our team casting in our old building.
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Pacific Kiln & Insulation Co. Inc.
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Pacific Kiln & Insulations Co. Inc.
info@pacifickiln.com Phone 951-697-4422 Fax: 951-697-4442
Pacific Kiln & Insulation Co. Inc.
info@pacifickiln.com
Phone: 951-697-4422 • Fax: 951-697-4442 26 ❘ September 2019 ®
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Pacific Kiln & Insulation Co. Inc.
info@pacifickiln.com Phone: 909.875-6331 • Fax: 909.875-9331
Pacific Kiln & Insulation Co. Inc.
info@pacifickiln.com
Phone: 951-697-4422 • Fax: 951-697-4442
The ceramic shell process was a particularly crucial step forward for the industry. As far as art foundries go, we were an early adopter of the technology. To take the medallion from concept
to reality, we used various software specializing in one or two specific tasks. The photo was taken into an image editor to add the border, text, and logo. Different shades of white, grey, and black in the image gave the software an indication of the depth each part of the image would be. The next step used a small application that created a depth map of the image and outputs a 3D file with all elements including the logo either raised or lowered to create a low relief. Lastly, the 3D file was imported into a CAD suite to adjust the shape and size of the final file used to make the master. The master was printed on a desktop
SLA 3D printer. The SLA printers offer excellent surface quality and material properties for art casting application. Although printing works well for awards and other low volume but repeating projects, in this case, we chose to print one medallion and make a rubber mold for future copies. From the flexible tooling the production process is the same as any investment casting foundry. Our final stage is an application of the Patina. This specific patina is called a Liver-Ferric. Liver-ferric is a combination of as base-coat of dark brown with a topcoat of a honey gold color. The unique thing about the Casting Contest Medallion is that as technologies change and improve, we will continue to update the relief. This is currently the 5th year of the ICI Casting Contest Medallion as well as the 2nd iteration of the medallion’s design.
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