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Blight'd Mastersword

The Reference

Making The Blade Mold

Pouring The Blade

Mix of Aluminum and Silicon

The Silicon helps the aluminum's flow rate so that when it pours it fills more pockets of the mold without issue.

Making The Guard, Handle and Pommel

At first there was an attempt to make the guard and handle as 2 different parts. However there were some flaws that appeared in the casting process where the metal was not flowing through and filling all the necessary channels.

When deciding the best way to proceed, I decided it might be worth trying to push more metal through the mold and with the extra volume there'd be more mass and weight to push into the smaller channels as well as more volume that'd take longer for the temp to cool and thus become harder to flow.

Making A Flask

Since we were going to be pushing a larger volume of our aluminum:silicone mixture, I thought it might be worth it to try and expand the scope of the mold and instead of casting the guard and handle in 2 parts, we'd instead do a split down the middle but have the guard, handle and pommel be all one component.

To help accomplish this, I constructed a T-shaped casting mold that would fit the 3D printed shape we were using to make our mold

Pouring The Guard, Handle and Pommel

Inspecting The Results

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