Working with low melt metals, like pewter, can be really fun! Pewter (and other alloys containing bismuth, tin, and lead) have low enough melting temperatures that you can cast them at home or in a workshop with having to buy or build a foundry. See also What is the cause of earth fault? Can you put pewter in silicone mold?
If you only require 10-20 cast parts, then you might opt to use less-expensive polyurethane mold rubber. Upwards of one hundred parts can be cast in these molds. Polyurethane and Polyester Resins– As mentioned in the previous section, silicone rubbers are generally the best option for casting these materials. What is the best material to use in silicone molds? The remaining liquid is then poured out to leave a hollow shell. In the process the material is poured into the mold and allowed to cool until a shell of material forms in the mold. Slush casting is a variant of permanent molding casting to create a hollow casting or hollow cast. Also, the sulfur in the gypsum reacts with iron, making it unsuitable for casting ferrous materials. The maximum working temperature of plaster is 1,200 ☌ (2,200 ☏), so higher melting temperature materials would melt the plaster mold. The fine powder forms a supersmooth mixture that dries to a rigid mold with high absorbency, which helps to pull water from the slip while preventing cracks.
This is the best choice for artists who work mostly with clay and need material for slip casting. What type of plaster is used for casting? What metals are easiest to cast? Aluminum is an easy material for metal casting because it is inexpensive, widely available, and melts quickly with a propane torch or in an electric kiln. The major disadvantage of plaster mold casting is that it can only be used with lower melting temperature non-ferrous materials, such as aluminum, zinc, magnesium, and sometimes copper alloys. See also Is the glue in plywood toxic? Can you cast aluminum in a plaster mold?
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