It has been some time since the last writing. This is because we have been extremely busy bringing our small foundry online.
It has been a bigger job than I anticipated. Each step involved exposed new lessons to be learned. Foundry work can be quite dangerous if done haphazardly. It can be very safe if done properly.
In reality, as with all our processes, the learning curve will never end.
We did not take the easiest route. We started right out casting brass instead of aluminum. Brass casts much hotter than aluminum and requires a more stringent process and safety considerations.
Another factor in the development of our process is that we are not looking to duplicate one or two parts. We are setting up to make 100′s of a particular part. This means that our patterns and tooling must be made to last and when the casting is complete have the least finishing work.
Like engraving, electroplating, and every other process we do in our operations to create our door knocker and door plates, there are many steps involved in the casting of each part. Every step must be performed correctly in the correct order or the final product will not be good.
Our little foundry has presented us with many challenges. It has also created much pride in the successes we have achieved. It is a very specialized foundry designed for the purpose of creating some very special items for our customers.
We do not intend to do all of our products castings here. There is just not enough hours in the day for that. Besides, if we made this a large production foundry it would not be as much fun.
Our castings combined with our nickel and copper plating and engraving capabilities will combine to make some very special items for our customers.
Very soon we will be announcing another YDK door knocker. This one is special as the patterns are being made from my own original carvings.
We will announce it here.
