Casting

All cast products require a pattern to cast from. This is an exact replica of the finished product usually made from rubber or wood. Some casting patterns have to be made to order, others, such as standard fonts or tourist symbols, are available from stock.

Once the pattern is produced, it is used to create a mould from very fine sand. Molten metal, usually aluminium or bronze, is then poured into the mould and allowed to harden. Once set, the finished item is fettled to clean up mould marks and prepared for final presentation.

Although a relatively crude process, casting can produce text to a minimum 7.5mm cap height. The detailing of finished items is usually done by hand.