Using sand casting as a technique, developed a Wine bottle stopper with aluminium.
Sand casting is a metal casting process considered by using sand as the mold material.
Sand casting is relatively cheap and sufficiently headstrong even for steel foundry use.
In addition to the sand which is called Silicon, a suitable bonding agent (usually clay)
is mixed or occurs with the sand. The mixture is moistened, typically with water, but sometimes with other substances, to develop strength and plasticity of the clay and to make the aggregate suitable for molding.
The sand is typically contained in system of frames or mold boxes known as a flask.
The mold cavities and gate system are created by compacting the sand around models, or patterns, or carved directly into the sand.
Ideation sketches
While on this process I wondered if this design would work or not, will it be strong enough?
Things like these started to frustrate me. Then came up with an idea which was perfectly
going well with the product use.
I chose the racetrack so that while opening the bottle, one will have a handle like grip to pull it out.
I had many iterations according to my likings in mind for the upper element to beautify it, which I got it laser cut.
Being a Formula1 Race fan and having a favorite racetrack, I chose the Formula1 Grand Prix Monaco Racetrack as my final element.
I created this prototype sticking several sun board pieces together, cutting it and then sanding it to get a finished conical shape. Then attaching the laser cut MDF (Medium Density Firewood) piece to get it sand casted.
The raw product after getting the prototype sand casted in aluminium.
While in the process of sand casting, I realised that the middle part of the racetrack needs to be added, so that it stays strong and sturdy. Then filled the space in the middle with the cut out, and went forth with it.
Then the time came for the grinding, fining, sanding and then buffing the product thoroughly to get the final outcome.
By making this I learned the whole process of sand casting and how its been used a lot commercially these days and becoming advantageous in many ways.
This is the first time I worked with the material metal, and faced a lot of challenges.
