Picture Time #2 - Ceramics and Foundry Demonstration

The staff at Arcosanti were kind enough to stop their workday and give in-depth demonstrations and explanations for the bell-making processes, both ceramic and bronze-cast. Here are the pictures that pretty much record that.





Demonstrating the silt-cast method (slip is poured into a mold made out of river silt, or very fine sand, to create a one-shot form without any handbuilding or wheel throwing).




The kiln. The ceramicists here actually fire their pieces straight from greenware to full bells, even if glaze is applied. I had never known this was even possible, much less it being done. They've certainly gotten their bell-making process down to a science.



Unfired bells.




Plaster molds.



Then, onto the Foundry. I think this is one of the coolest places at Arcosanti.



Jim showing us the aluminum molds.




Unassembled bronze bells.



Bronze tiles.



Molds awaiting the bronze. The molten bronze is poured into a very fine quartz dust, which takes the shape of the aluminum molds.




Compressing the quartz dust.



Before pouring designs are added to the interior of the molds, which leave relief impressions. We were actually allowed to create our own impressions in the bells. Here is Gen working on his variation.



Where the bronze melts.



Clearing out the sprues for the molds (the place where the metal flows in).



Finally, the bronze is ready.




Pouring.





The bells cool and then busted out of the molds. The sprues are cut off and recycled as scrap bronze for the next firing, and the bells eventually get assembled.