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Casting, Part 1

February 21, 2015 By Danielle

I’m in San Francisco for a class in casting at Revere Academy — MOLTEN METAL, AWWWWW YEAHHHHHHH — and wanted to share what I’ve done so far. There’s a lot to learn about the process, combining skills of working with wax, using molds, calculating metal requirements, setting up the investment (plaster mold formed around the wax or object), and the actual casting of the metal.

Whole succulents, cast in bronze by Jonathan Russell. Whole jade plant, cast in bronze by Jonathan Russell.

These are a couple of examples of succulents cast by my instructor, and the detail and texture on them is just mind-boggling. I was instantly obsessed with the idea, and hopefully tomorrow it will come to fruition! (More on that later. There’s a cactus of some sort, a sempervivum, and a zebra plant in that first picture.) I ran right out Friday evening and bought some succulents to sacrifice for the greater good cast.

Taking a cooled, injected wax out of a mold. Harder than it looks. Six waxes I made from molds, ready to assemble into a "wax tree". Waxes, assemble!

The first part of the class was to inject wax into molds (supplied by the school, unless you had your own), and assemble several waxes into a cast-able “tree” that fit the dimensions of the flask — not as easy as it sounds. This tree wasn’t actually cast — just an exercise in how to assemble a tree for casting. By angling things right, dozens of small pieces can be cast all at once, in one flask. (If you’re wondering, among other things on my tree is a LEGO stormtrooper helmet, and half a washer. You can mold darn near anything.)

A wax ring I carved in August 2013, fitted to the base of the flask. Flask assembled and ready to invest.
Mixing the investment... ...mixing goes faster in a stand mixer. Flasks under vacuum, to remove air bubbles from the investment before it hardens.

I decided to cast one of the wax rings I made in Wax Carving class, back in August 2013, as my first actual project (green wax.) This first casting uses the centrifugal method, which is… action-packed. (I’ll get to that in a minute.) I mounted the wax to the base of the flask using sprue wax (yellow and red wax), which will provide a conduit through the plaster for the metal to be poured in. (What you’re looking at now will be upside-down, when cast. A sprue is just a conduit for metal to flow through, and one piece can have multiple sprues, to aid in the flow.) Once the flask is assembled, a kind of plaster called investment is mixed, put under vacuum to remove air bubbles, then quickly poured into the flasks, and then the flasks are put under vacuum to remove air bubbles from around the wax, which would mar the mold. There’s only about 12 minutes to go from mixer to poured, to bubble-free and sitting in a safe place, so the process is a little intense.

Maybe I should say, the class is a little intense.

So all of that was day 1. Once hardened, these flasks are placed in a kiln overnight to burn off the wax, and any carbon or moisture that remains, and held at a temperature optimal for the casting process (which varies; ours were 950° F.) Today was day 2, and we started casting immediately after lunch. Guess who got picked to be first? (I probably looked like a deer in headlights.) So here we go…

The crucible part of the centrifuge, where the metal is melted. Here I am, not remembering which direction to turn the knobs to light the torch, because I'M BACKWARDS, OKAY?? Heating the silver until molten. Stirring the silver with a rod of carbon, which removes oxygen from the molten metal Just about ready to cast now... Once the flask is in place (in the gap between the crucible and the plate at the left side of the last frame), I take away the torch, and my partner sets the centrifuge off. Once the spinning stops, the flask is removed with tongs (still extremely hot.) The dark spot in the center of the white is the metal. Once the flask cools for a few minutes, it is quenched in water, which simultaneously cools the metal completely, and dissolves the investment plaster. Imagine holding a tiny jacuzzi in tongs, underwater, trying not to pull it out or... panic. And here's the cast ring! Cast ring, pickled to remove oxidation.

So. Centrifugal casting. (Did I mention I was being quizzed on each step in the process? NO PRESSURE…)

The open drum is wound up with a handle, that can be locked in place. You wind it up, then lock it, then place your metal in the crucible and start melting. Once the silver is perfectly melted and prepped, a partner places your flask (which has been in a kiln heating the whole time) next to the crucible, you take the torch away, and the partner unlocks the centrifuge, which spins at great speed, flinging the molten metal into your mold. (It’s a little scary.) Once the drum spins down, the flask can be removed, set aside to cool for a few minutes, before quenching it in water to simultaneously cool the metal and dissolve the investment plaster. Once it’s done violently bubbling underwater — INTENSE — you can pull it out and grab your finished piece! My ring turned out great, and it’s ready to trim, finish and polish.

In reality, it was a blessing to go first, because then it was done, I was relieved, and I could spend the rest of the afternoon preparing my second piece for tomorrow’s vacuum casting…

The succulents I picked to cast: an echiveria with bloom, gollum jade, and another jade (that came with the pot.) Assembled succulent leaves, mounted on toothpicks and stuck together with sticky wax. I'm using gollum jade and zebra plant leaves, which should reproduce in fine detailed texture... And here they are, ready to invest!

So in the end, I wasn’t able to use the succulents I’d hoped to cast as whole plants, due to space limitations. Instead, I created a “bouquet” of gollum jade leaves, and zebra plant leaves, which I mounted… creatively… into a flask. I won’t know until tomorrow how it all held up under the investment, but I’m hoping for the best! (Unlike waxes, organic items can’t be vacuumed once invested, as the vacuum will crush the organic materials and ruin the mold. You just have to tap the sides of the flask and hope all the bubbles dislodge before it hardens.) I will be casting it in bronze, as I love the look of the instructor’s examples, and it may be an opportunity to try some patinas, on my own time.

Tomorrow will be vacuum casting, which has less open swinging flames, but just as much molten metal (more, actually, since I’m making a larger piece.) I hope to have more action shots! A GIGANTIC thank you to Aussie classmate Diane for her barrage of photos of my casting experience!!

Thanks for reading to the end, and I hope you enjoyed the blow-by-blow commentary!

Filed Under: Goldsmithing & Jewelry Tagged With: casting, goldsmithing, Revere Academy

Fabrication 3: Construction

September 16, 2014 By Danielle

As promised, here are my photos from the Fabrication 3 class I took at Revere in July. The two projects were a sweat-soldered layered brooch, and a hollow box ring.

The brooch was a fun project, as we used a rolling mill to impress the silver with patterns from fabric, paper, and plastic textures. I patterned the base of my brooch with a glittery tulle fabric, and paper-punched snowflakes. The top layer was rolled with 220-grit sandpaper. I domed the two layers, then soldered them together (which was harder than I bargained for, LOL), and soldered on the back pin hinge and catch.

Materials for patterning metals with the rolling mill, July 2014
Design sketches, materials for patterning metals with the rolling mill.
Bottom silver sheet for brooch, with patterning materials, July 2014
Bottom silver sheet for brooch, with patterning materials.
Patterned top and bottom silver sheets for brooch, July 2014
Patterned top and bottom silver sheets for brooch.
Top layer shaped and domed for brooch, July 2014
Top layer shaped and domed for brooch.
Top and bottom layers domed, ready for soldering, July 2014
Top and bottom layers domed, ready for soldering.
Top and bottom soldered together, July 2014
Top and bottom brooch layers soldered together.
Ready to solder on the brooch hinge and catch, July 2014
Ready to solder on the brooch hinge and catch.
Pin attached, not long enough! July 2014
Pin attached, not long enough!
Brooch pin adjusted to stretch across, whew! July 2014
Brooch pin adjusted to stretch across, whew!
Finished brooch, July 2014
Finished brooch.

The hollow box ring was quite challenging. It starts as two long strips, the inner ring and outer wall. The inner strip is soldered together into a ring; the outer strip is soldered to the outside of the inner ring. In the end, the bottom half of the ring is solid metal, and the top is hollow. Once attached, these are soldered onto a flat sheet, forming the first side of the hollow ring, which is then cut out from the sheet and cut out on the inside (remaking the finger hole, basically.) Once this is done, you repeat the process with the other side, forming a box ring with an open top.

There’s a lot of filing and finishing to be done at this point, to make all the corners square and flush. A pattern is chosen for the top, and the final bit of soldering is done (there must be a hole either in the top piece, or drilled through the bottom part of the hollow ring, else the ring will explode during the final solder. No, really.) I got as far as soldering the top on, and then finished the final trimming, filing and polishing closer to home.

An assortment of hollow box rings, in various stages of completion and decoration.
An assortment of hollow box rings, in various stages of completion and decoration.
Soldering the inner and outer ring shank together.
Soldering the inner and outer ring shank together.
Inner and outer shanks attached, filed flat.
Ready to solder on the first side!
Ready to solder on the first side!
First side soldered on, pre-pickling (not cleaned)
First side soldered on, pre-pickling (not cleaned)
PIckled, ready to cut out inner hole and outer shape.
PIckled, ready to cut out inner hole and outer shape.
All cut out, and ready for side two!
All cut out, and ready for side two!
Side two soldered on, ready to pickle.
Side two soldered on, ready to pickle.
Both sides cut out, ready to file and sand.
Both sides cut out, ready to file and sand.
Filed and sanded, ready to solder on the top.
Filed and sanded, ready to solder on the top.
Another view, pre-top.
Another view, pre-top.
Top soldered on, just needs to be trimmed, filed, and polished.
Top soldered on, just needs to be trimmed, filed, and polished.
Finished hollow box ring, July 2014
Finished hollow box ring, July 2014

Filed Under: Goldsmithing & Jewelry Tagged With: brooches, goldsmithing, jewelry, rings

Just keep making.

September 13, 2014 By Danielle

If you follow my Instagram, you’ve seen that I’ve been busy this summer, making jewelry. I’ve been meaning to repost those progress photos here for a while, but, well, here it is, September. (I need to repost my Fabrication 3 class photos, too.)

I’ve been making a lot of pendants, and now I’m trying my hand at some earrings. Rings are always happening, I can’t make enough rings. A lot of the stones I have now are more pendant-size, but there will still be a few rings in there. And at least one pair of earrings. Stay tuned. [Read more…]

Filed Under: Goldsmithing & Jewelry Tagged With: goldsmithing, jasper, jewelry, labradorite, pendants, rhodochrosite, rings, ruby, turquoise

The short, short version.

July 24, 2014 By Danielle

Revere Academy classroomI have about three posts I could write about the last week, but in the interest of time and actually POSTING something, I offer you some bullet points, to be embellished later on.

  • I held a mechanical watch in my hands, for the very first time ever. Now I know what watch experts mean, when they talk about the “heartbeat”. IT WAS SO COOL. I TOTALLY WANT ONE.
  • I went to Revere Academy last weekend for the Fabrication 3 course. Made a layered, sweat-soldered brooch, and a hollow “box” ring.
  • I “live-shared” my Fab3 experience via Instagram, reposted to Facebook and Twitter, so if you want to see the stages of construction on both pieces, click the link to see my photostream. I will repost those images here, later.

Filed Under: Goldsmithing & Jewelry Tagged With: goldsmithing

Spring jewelry creations

April 3, 2014 By Danielle

Just a quickie post to show off my two newest pieces: a synthetic opal ring, and a coated drusy quartz pendant.

Synthetic opal ring by Danielle Rose, March 2014
Synthetic opal ring by Danielle Rose, March 2014
Synthetic opal ring by Danielle Rose, March 2014 Synthetic opal ring by Danielle Rose, March 2014 Synthetic opal ring by Danielle Rose, March 2014 Synthetic opal ring (in progress) by Danielle Rose, March 2014
Quartz drusy pendant by Danielle Rose, March 2014
Quartz drusy pendant by Danielle Rose, March 2014
Quartz drusy pendant by Danielle Rose, March 2014 Quartz drusy pendant by Danielle Rose, March 2014 Back of quartz drusy pendant by Danielle Rose, March 2014

Filed Under: Goldsmithing & Jewelry Tagged With: goldsmithing, jewelry, opal, pendants, quartz, rings

Fabrication 2: Toggle Bracelet

January 17, 2014 By Danielle

My in-progress pictures of the first two projects of Fab 2 didn’t turn out, and I haven’t taken pictures of the finished results (such as they are.) For now, I’ll just mention them: the first project was a twisted wire ring of silver and copper, designed to be seamless (tricky, since you have to exactly match the twists where you cut), with both wires soldered shut (tricky, since the metals solder at different temperatures.) The second was a carved ring, starting from a square cast silver ring, which was divided into quarters and carved (filed) into a half-dome section, a fully round section, and a twisted pattern section.

Mostly I was occupied with the third project, which took about half the class hours to construct. Submitted for your approval: the Toggle Bracelet.

The "materials kit" for Fabrication 2.

As hard as it is for me to believe, wearing it, the toggle bracelet started as that large coil of silver wire in the picture. (Yep, everything you are about to see came out of that coil. It’s crazy. Stay with me here.) We started by measuring out and setting aside a portion of wire, in order to construct the toggle clasp part of the bracelet.

We created a toggle bar from wire, attached it to a figure-eight connector made from a pair of smaller jump rings soldered together, and melted two other small jump rings to create a ball for each end of the bar. The loop was created from wire, soldered, and hammered into a round shape, then sawn back open so as to insert the other figure-eight loop that attached it to the bracelet, and solder it shut again. (You solder it shut initially so you can hammer it into a circle, which you couldn’t do if the connector was already on it.)

Fabrication 2: Look at all them jump rings!

The rest of the wire, we coiled around a mandrel (steel rod) to form a long spring. This, we carefully sawed through, creating jump rings (or links, or loops.) A LOT of jump rings.

(Guess what a chain bracelet is made of? A WHOLE LOTTA JUMP RINGS, FOLKS.)

Fabrication 2: Pick-soldering jump rings closed.

Since all the links on the chain needed to be soldered shut, we started by soldering half the jump rings shut. I can now say I can competently pick-solder. (All it means is, instead of laying a chip of solder directly on the seam and heating the piece until it flows, you melt the solder separately, pick up the solder on the point of your soldering pick — a pointed rod that doesn’t solder to anything, in a wooden handle so it doesn’t burn you — heat the piece, and touch the solder to the seam once the temperature is right. It sounds complicated, but it makes soldering jobs like this go very quickly.)

Fabrication 2: Finished length of chain, which I forgot to measure to fit my wrist.

Once this initial batch is done, you start assembly, by taking an open jump ring, stringing two closed rings on, then soldering the open one shut to make chains of three. Then you connect two threes with a ring and make sevens, connect sevens to make fifteens, etc, until you have a finished length of chain. Somewhere in there, you stop and measure the chain against your wrist, and stop at a certain length — in my frenzy to complete the bracelet by the end of the class, I sortof forgot that step, which is why my bracelet is about an inch too long. [sigh]

Anyway, here it is. Hard to take a picture of a bracelet while you’re wearing it…

Fabrication 2: Completed chain bracelet with toggle clasp.

Filed Under: Goldsmithing & Jewelry Tagged With: goldsmithing

Fabrication 1

January 13, 2014 By Danielle

I’m taking the first two fabrication classes at Revere Academy of Jewelry Arts in San Francisco this week (just finished Fabrication 1 yesterday; starting Fabrication 2 today. I never did talk about the wax carving class I took here last summer; is anyone interested? I suppose posting belatedly is better than not posting at all.)

Although I had some soldering experience, enough that I debated skipping Fab 1, I really learned a ton in the past three days. It went far beyond basic soldering skills; we also learned how to saw, file, sand, buff, and polish. We learned about tools — we made tools. I had no idea how little I understood about metals and hardness. It was quite an experience.

Fabrication 1: earrings. At this point they are glued together and sawn as one unit, so they'll match exactly.

Probably the most complex project we made was a pair of pierced (cut-out), domed earrings in a matched geometric pattern. (Apologies in advance for my crummy phone-camera pictures; it never seems to focus on what I’m photographing.) We started by cleaning two pieces of silver and gluing them together, then gluing on a pattern to cut out. Holes are drilled in the middle of each cut-out, so a saw blade can be strung through and each section can be sawed out. Once the interior cuts are done, the outside is sawed to form a circle. The piece is then filed as a unit, to smooth out the cut-outs and the outside, before the pieces are separated into a matched set.

Fabrication 1: earrings, separated and domed

Once separated, the earrings are domed using a dapping block — a cube with half-round holes in it, of various sizes; you stick the flat piece into the size you want, then use a large peg with a spherical end (a dap) and a mallet to form the domed shape. After this, additional filing is done to the individual earrings, and a lot of sanding to remove any file marks, scratches or pits. Once this is done, the pieces are buffed, earring posts are soldered onto the back, then another trip through the buffer and final polishing is done.

We also made three rings: one in nickel, using round wire; one in silver, using square wire; and one in gold-fill, using half-round wire. In each case, we learned to properly calculate the length of wire needed to accurately size the ring, soldered it appropriately based on what type of metal it was, and clean up the solder joint to form a seamless ring. (Your seamless-ness may vary, though I’m happy enough with them that I’m wearing them all at once. Jewelry class is making me particularly bling-tastic, today.)

Finally, yesterday afternoon, we made a small bezel pendant with an onyx stone, with a soldered jump ring. Although I’ve made many a bezel setting before, I learned a new method of doing it, and this was by far the smallest bezel I’ve made or set.

Here’s the finished pieces!

Fabrication 1: pierced domed earrings; three rings in nickel, silver, and gold; bezel pendant.
Fabrication 1: pierced domed earrings; three rings in nickel, silver, and gold; bezel pendant.

Filed Under: Goldsmithing & Jewelry Tagged With: goldsmithing

Wayback Machine: More jewelry, more stones

January 13, 2014 By Danielle

Before I post new things, let me show you some jewelry pieces I made last summer and fall…

In August, I made two labradorite rings (one for me, one for a friend), and a labradorite cuff bracelet that I adore, for me. Very pleased with how these three came out!

Labradorite cuff bracelet, sterling silver, August 2013 Labradorite rings, sterling silver, August 2013

I then had a two month hiatus while my local teacher was out of town. In November, I made two pendants, both turquoise: one was a commission from my friend Annie, using turquoise from a specific mine (Morenci); the other used Hubei turquoise from China, and is rather large. I may wear it if I can figure out an appropriately big chain for it (and work up the nerve.)

Morenci turquoise pendant for Annie, sterling silver, November 2013 Hubei turquoise pendant, sterling silver, November 2013

Filed Under: Goldsmithing & Jewelry Tagged With: goldsmithing, labradorite, turquoise

Turning over a new… facet?

October 24, 2013 By Danielle

So it occurs to me that I’ve only posted five times this year. No good excuse for that, really. Is anyone still reading? [crickets]

I can’t seem to find a theme I like, my topics bounce around… well, let’s face it, I’d rather fiddle with the stylesheet than write a post. I like thinking about writing posts, but no posts actually get written. I still like posting jewelry pictures though, so my Pinterest boards are reasonably active. I’ve started two “visual archive” type blogs, on ancient and antique jewelry, as a sort of miniature, self-hosted Pinterest. (For a few reasons. Read about them here.)

Since last we met, I took a wonderful class on carving wax models for casting (which I didn’t blog about), and have had the past two months off my jewelry lessons, as my teacher was on the road (nothing to blog about.) I have finished a few more stone boxes for Gem Ident (blog-worthy), and have a goal to be done with the boxes by early January (highly blog-worthy, should it occur as scheduled.) I have my eye on several museum exhibition catalogs, as there’s a lot of amazing jewelry exhibits on, mostly in places I’m unable to visit (questionably blog-worthy?)

I expect to start making jewelry pieces for sale this fall/winter, once I have access to a workshop again. I am taking commissions on a very limited basis (limited by time — I have very little of it.) For now, I work in sterling silver, with the loveliest stones I can get my hands on. I really need to revive my Etsy and list my resin pieces there, if there’s interest. (Hint: comment if interested.)

A note for subscribers: I have changed the subscribe-to-posts email service, so if you got two of these emailed to you, please keep the MailChimp one and unsubscribe from the other one. (The new one has a pretty amethyst graphic at the top.) If you only got the WordPress one, please unsubscribe, and fill in the form again here on the site to get on the new list. Finally, if you got this blog post and aren’t sure why, you joined a mailing list for my jewelry business, and I have combined two lists into one. (I promise not to post so often as to be annoying, but if this isn’t what you want to read, please feel free to unsubscribe.)

Filed Under: Detritus Tagged With: gem ident, goldsmithing, jewelry, museums

Twelve Weeks of Silversmithing

August 3, 2013 By Danielle

Rainbow moonstone pendant, May 2013

I know, I know. Twelve weeks of silversmithing lessons, and NO BLOG POST? (I need to write about Gemstone Identification as well; save that for another day.) What can I say? It’s been a busy spring summer year.

I started taking weekly silversmithing classes in Medford at the beginning of May, from Bob Sharp, a local jeweler and lapidary (and fellow Roxy Ann member.) I don’t have any of my own equipment yet, so it gives me a chance to practice the process of making things, with some help and supervision. I’ve made several pieces now, and I definitely think I’m improving, though I have a long way to go.

Finished larimar & rainbow moonstone pendant, May 2013

Mostly what I’ve made are bezel-set gemstone pendants. Nearly everything has been a gift — I like making jewelry for other people, that’s nothing new. My first piece (left) was for my sister’s 25th birthday, and was probably more complicated than I should have attempted, but I think it came out well.

Bezels, before trimming, one got a little... melted. July 2013

It’s been an interesting few months. Soldering is getting easier, but it can still be mysterious (did I say mysterious? I meant “insanely difficult”.) Sometimes, things don’t go as expected (example at right: partially melted/burnt bezel, top right.) Sometimes the stone isn’t really cut well for setting. Sometimes I file really well, and sometimes I file off part of my fingernail (in a bad way.) Some nights I get a ton done in three hours, and other nights (like this past Thursday), every tool I need to use is malfunctioning, and everything I do takes three times as long as it should.

I have two more weeks of class. At the end of August, my teacher is out of town for two months, so I’m finishing up two more pieces (a bracelet, and a ring), and then I’ll have a break. I’m trying (when I remember to bring my camera) to document the process, so you can see how it starts, what the middle stages look like, and how it comes out as a finished piece. Enjoy the photos!

Rainbow moonstone pendant, May 2013

Star ruby and labradorite pendants, June 2013

Star ruby and labradorite pendants, June 2013

Finished larimar and quartz drusy pendants, July 2013

Pendant bezels in progress, July 2013

Finished larimar & rainbow moonstone pendant, May 2013

Larimar & rainbow moonstone pendant, in progress, May 2013

Small labradorite cabochon and bezel (for a ring), in progress, July 2013

Larimar and quartz drusy pendants, in progress, July 2013

Quartz drusy pendant, in progress, July 2013

Labradorite cabochons and bezels in progress, July 2013

Larimar pendant, in progress, July 2013

Filed Under: Goldsmithing & Jewelry Tagged With: goldsmithing

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