So right now I am in Mátranovák, Hungary. I have spent the last few days sand casting hammers in brass. The first one I tried was the seahorse claw hammer.
I made the sand casting mold in the usual way. First I compacted the sand into the bottom part of the mold. After scraping the sand flat I roughly carved out a space for the 3D printed hammer.
I compacted the sand flat around the centre line of the print and then coated in talc.
I added the top part of the mold and compacted the sand with a mallet. After reaching over the top line I scraped back the top so it was flat.
I then opened the mold and took out the 3D printed plastic hammer and the tube I used for the pour hole.
I placed the mold back together and clamped the edges.
I then took the mold to the local blacksmith Laci bácsi, who helped me cast the piece in Brass.
He first smashed up lots of pieces of coal into small pieces for the furnace.
He then lit the furnace with some small pieces of wood and then added the coal.
After around five minutes after the pour the metal was solid enough to open the mold.
Laci bácsi and myself were both very happy with the result.