Casting & Molding
This project explores the intersection of modern fabrication techniques and traditional casting methods to recreate a miniature figurine inspired by Cleopatra's funerary mask. By utilizing CAD modeling in Rhino, 3D printing, and silicone molding, followed by molten metal casting, this process captures intricate details and brings historical designs to life. The outcome is a blend of precision engineering and artisanal craft, showcasing how contemporary technologies can preserve and reinterpret ancient artistic heritage.
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The Background
Queen Cleopatra VII, the last ruler of the Ptolemaic Kingdom of Egypt, was a powerful and astute leader known for her intelligence, diplomatic skills, and political alliances. Fluent in several languages, she was deeply involved in governing Egypt, expanding its wealth, and securing its independence through strategic partnerships with Roman leaders Julius Caesar and Mark Antony. Cleopatra used her influence to maintain Egypt’s autonomy amid Roman expansion, embodying a rare blend of political and cultural power. Cleopatra's ability to navigate the complex political landscape of Rome allowed her to secure alliances that protected Egypt’s sovereignty for as long as possible. Even after her defeat and tragic death, her story has endured as a symbol of resilience, intellect, and the enduring allure of one of history’s most enigmatic figures. Her physical depiction varied across civilizations: Egyptian portrayals showed her as a divine, regal figure with traditional symbols of royalty, while Roman depictions often emphasized exotic beauty, aligning with their narratives of seduction and conquest. These contrasting images reflect her complex legacy as both a powerful ruler and a figure of fascination, blending myth and reality.
I decided to make a figurine of what would be Cleopatra’s funerary mask.
The Works
Making the Mold
3D Modeling and Design:
Using Rhino, a 3D model of a stylized Cleopatra funerary mask was created. The model included intricate details to capture the essence of the ancient design. After the design was finalized, a 3D print of the mold dish was generated, which would be used to make a silicone rubber mold.
Preparing the Mold:
The OOMOO silicone rubber was chosen for its flexibility and ability to capture fine details. The components of the OOMOO rubber were mixed thoroughly and poured into the 3D printed dish, ensuring an even and bubble-free pour. The silicone was allowed to cure, forming a durable and detailed two-part mold.Demolding and Mold Preparation:
Once cured, the mold was carefully removed from the 3D printed dish, revealing a precise cavity matching the 3D model. However, due to the miniature size, it was hard to tell how well the mold captured the details of the face, jewelry, and hair.
Casting the Queen’s Mask
1. Applying Corn Starch:
The mold surfaces were prepped using cornstarch to facilitate easy release during the casting process. The cornstarch acted as a fine release agent, preventing the molten metal from sticking to the silicone and ensuring a clean, detailed extraction of the figurine.
2. Casting with Tin Alloy:
Molten tin alloy was heated to the appropriate temperature and carefully poured into the silicone mold cavity. Safety precautions, including gloves and protective gear, were adhered to during this process to manage the molten metal safely. The alloy cooled and solidified, taking the shape of the figurine.
3. Finishing Touches:
After the tin figurine was extracted from the mold, minor finishing processes were performed to remove any excess material or imperfections. The final piece displayed intricate details, preserving the likeness and craftsmanship inspired by ancient Egyptian artifacts.
The Final Product
The final product, a miniature figurine of Cleopatra's funerary mask, showcases a blend of craftsmanship and historical representation. Cast from molten tin alloy using a silicone mold, the figurine reflects the intricate design elements of the original 3D model, particularly in the hair and headdress patterns. However, due to its reduced scale, some of the finer details, especially those of the facial features, were less pronounced. The miniaturization process limited the mold’s ability to capture subtle nuances, resulting in a piece that, while still recognizable, did not fully convey the delicate expression and intricate details of Cleopatra’s face as intended. Despite this, the figurine succeeded in maintaining the overall aesthetic of the design, with clear contours and textures that highlight the regal and iconic attributes of the ancient mask. The metallic sheen of the tin alloy added a visual quality reminiscent of ancient artifacts, giving the piece an authentic, almost antiqued feel. Overall, the project served as a testament to the ability of modern casting techniques to recreate historical designs, while also highlighting the challenges of scaling down intricate features without loss of detail.
Behind the Scenes: learning together & learning from each other.
Learning the molding and casting process was a collaborative experience facilitated through the Arch team workshop. Initially, the team focused on preparing silicone molds using OOMOO rubber, guided by step-by-step instructions to ensure proper mixing, pouring, and curing. Working together allowed us to streamline the preparation, with each person assigned specific tasks to expedite the process. Later, a smaller sub-group within the workshop, led by Jacob, taught the technique of special casting with tin alloy. Handling molten metal required precision and safety, making teamwork essential. Having more than one person allowed tasks to be divided, such as pouring the molten metal while simultaneously shaking the mold to avoid air bubbles. This not only sped up the process but also ensured safety measures were upheld, reducing risks. The hands-on approach, combined with group coordination, made the entire learning process efficient, informative, and safe.