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The Making Process

Updated: Oct 28, 2020

You may have seen our finished light switches, power sockets and other products but have you ever wondered how these products are made?


In this post, we will give you a glimpse into life at the foundry with a step by step guide on how we create our bespoke pieces.


1) Creating the Pattern

The first step in the making process is creating the pattern.


Our pattern making process has changed over the years and now uses a combination of computer design, 3D printing methods, and manual work. This is to ensure the patterns are perfectly made and can withstand daily use.


Although some of the design process is done on the computer, our designs are all the product of our designers mind and everything is sketched and detailed by hand to begin with.


Then, once the pattern has been printed, the finish is all done by hand.


2) Boxing up

The pattern is mounted on a board, filled, rubbed down, painted and polished, after which it's time to use it to create the mould for metal to be poured in to. This is done by using traditional sand casting methods.


The pattern is put into a box, with the box able to split into two halves. Sand is then packed around the pattern, before being turned over and sand packed into the other side as well. A sprue is made in this side of the box in order for the liquid metal to be poured in.


Once the sand is tightly packed in, the box is split and the pattern removed to leave a void in the sand. This void is where the metal will be poured.


3) Pouring the Metal

After the patterns are boxed up, it is time to make the product. This is done by pouring molten metal into the box, with it filling up the void left in the sand and setting.


First, the furnace is heated in order to melt the metal. Then, wearing the correct protective equipment, our casting technician pours the metal. These boxes are left to cool and then broken out to give us our castings.


4) Making Good and Machining

Once the castings have been broken out of the boxes, they are taken in to our machine room where the sprues are removed and the units made good. They are then drilled, tapped, switches or sockets put in and then the unit is assembled.


5) The Finishing Touches

After the units are assembled, they are given a light polish to clean them up but not remove any of the vintage look we are aiming for. They are then ready to be packed up and sent out.


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