Each new brass door knocker starts out with a design or idea of what it should look like.
Our brass door knocker starts out as a block of wood. In this case the wood is pine. The outline is cut to the approximate shape using the band saw. Most of the rest of the work is done by hand.
All the details are carved into the pattern just as we would like them on the finished product. The only things lacking in this picture are the hinge pins and the mounting lugs. These will be added next.
When the pattern is ready it is taken to the mold shop and tested in a sand mold. The pattern must be made so that it can be removed from the sand mold without taking any of the sand with it. This mold was packed for test purposes only. No sprues or gates are necessary for this test. Now we know that the pattern can be removed from the mold we will add the sprues and gates that will be the path of the molten brass to flow through and fill the cavity area left where the pattern was removed.