A friend of mine is a stained glass artist. She wants to do a stained glass Doctor Strange window. For those of you not familiar with the movie or the comic book this is what she wants me to cast for her.
Here's my problem. She wants the circle to be two foot in diameter and about 3mm thick. It also needs to be out of a metal she can solder to. In her case that is probably going to be a low melt metal like pewter.
I don't think ceramic shell would be a good fit because of the type of metal and the fact that it needs to be flat. Also my burn out kiln isn't big enough to hold that.
I was thinking sand casting might work. The only problem is this mold is going to have to be around 2 1/2 feet square. Will the sand stay in the mold if it's that large a flask? Is there a way to add support of some kind for the sand if it's needed?
I was planning on buying "real" green sand rather than make it if that makes any difference. I haven't had much luck making my own green sand.