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
-
Started with raw sand-cast iron parts containing gates, runners, vents, and residual sand from molding.
-
Removed excess material via band saw cutting and belt sanding to establish final geometry.
-
Sandblasted with Black Beauty abrasive to eliminate surface sand texture and create a uniform base finish.
-
Progressively refined surfaces using disc sanders, orbital sanders, and Dremels for detailed areas.
-
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.
Surface Finish Development
Progressively reduced surface roughness to influence patina absorption and visual depth. Finish level directly impacted chemical reaction behavior.
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.
