Iron Casting Post Processing
Surface Engineering & Patina Development
Led a post-processing initiative focused on transforming raw sand-cast iron components into refined, aesthetically controlled products. Developed a repeatable finishing workflow — from material removal to chemical patina application — emphasizing surface engineering, process control, and finish consistency.
Skills:
Industrial Design
CAD
Sketching
User Centered Design
Laser Cutting
Process
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Started with raw sand-cast iron parts containing gates, runners, vents, and residual sand from molding.
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Removed excess material via band saw cutting and belt sanding to establish final geometry.
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Sandblasted with Black Beauty abrasive to eliminate surface sand texture and create a uniform base finish.
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Progressively refined surfaces using disc sanders, orbital sanders, and Dremels for detailed areas.
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Applied chemical patinas, testing temperature variation, layering techniques, and surface preparation methods to control final coloration and texture.
Engineering & Design Focus
Manufacturing Cleanup & Geometry Control
Established a systematic removal process to eliminate casting artifacts while preserving dimensional integrity and form.
Surface Standardization
Used a sand blaster to normalize the rough sand-cast texture, creating a controlled baseline for finishing operations and consistent downstream results.
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Surface Finish Development
Progressively reduced surface roughness to influence patina absorption and visual depth. Finish level directly impacted chemical reaction behavior.
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Material & Chemical Experimentation
Tested patina application variables — including heat, layering, and surface preparation — to understand how thermal energy and surface roughness affect oxidation patterns and adhesion.
Process Repeatability
As project lead, developed and documented a structured workflow to improve consistency across castings, reducing variability in final aesthetic outcome.
