Casting

The casting process is a three phase process.

First, the wax mold needs to be prepared for casting. Using thin rods of wax (sprue), the mold is attached to a domed rubber base. The wax tubing will provide a channel for the molten metal to flow into the ring cavity.

A round, metal flask is tightly secured to the rubber base. Depending on the metal to be poured, a temperature-specific investment mixture is prepared and poured into the flask. The flask is left while the investment hardens.

The second phase is known as the "burnout." The rubber base is removed from the flask and the flask is placed in a kiln. Overnight, the kiln reaches temperatures exceeding 1600 degrees Fahrenheit and the wax evaporates out of the flask. Now there is an empty space inside in the exact shape of the desired piece. Every detail, down to the smallest bead, will be left behind.

The final phase is the actual casting.

At Joseph Jewelry, we use a high-tech, computerized casting machine. Most other jewelers heat the metal with a torch and guess when is the right time to release the molten metal. Being off by even a few degrees can increase the risk of porosity (small air bubbles in the metal). Porosity can be polished away on the surface of the metal, but as the metal wears down, small divots will begin to appear. Not only a cosmetic concern, porosity can be a structural concern as well, especially if located in the prongs.

Another benefit to using our casting machine is that it creates an Argon vacuum by removing all of the atmosphere and replacing it with Argon. Without Oxygen present, surface oxidization is impossible, so all casts come out perfectly clean every time.