Pattern Making: The Foundation of Accurate Metal Castings

Pattern making is one of the most critical stages of the metal casting process. A pattern is a wooden replica of the item to be cast in metal. The pattern is used to create a mold into which molten metal is poured to produce the casting.

Without accurate pattern making, even the best metals, alloys and casting processes cannot produce a high-quality result.

Making wooden patterns for metal casting involved carpentry expertise.

What is a pattern?

A pattern represents the shape, size, and features of the final casting. It accounts for factors such as metal shrinkage, machining allowances, and mold design.

Patterns can be made from materials such as wood, plastic, resin, or wax depending on the application and production volume.

At Adelaide Brass Castings, we specialise in handcrafting wooden patterns to create precise sand molds that deliver superior results. Wooden patterns are cost-effective for small to medium volumes, easy to modify or repair, and suitable for a variety of complex shapes.

How is a pattern made?

Typically, a pattern starts with a physical sample, existing item or engineering drawing of the desired metal casting. Often, it is a simple hand-drawn outline.

At Adelaide Brass Castings, our talented pattern-maker then uses advanced carpentry skills to transform this drawing into the pattern handmade from the most appropriate wood. If the casting requires internal cavities or hollowed areas, provisions are included in the pattern and these are known as 'cores'.

The timber is cut and shaped using hand tools and machinery, then the pieces are joined. Once shaped, the surface of the pattern is sanded smooth and sealed to improve mold quality and extends the pattern’s working life.

Why pattern accuracy matters

Accurate patterns ensure:

• dimensional consistency,

• reduced defects,

• better surface finish, and

• less machining (refining) after casting

From industrial and infrastructure projects to domestic works, pattern accuracy directly affects the performance and reliability of cast items.

Pattern making and custom castings

Pattern making is especially important for custom or replacement items, where no existing molds are available. At Adelaide Brass Castings, we often support equipment repair, heritage restoration, visual arts projects and commemorative works through bespoke pattern making.

Need a pattern made for a custom metal casting?

Accurate pattern making is essential for high-quality metal castings, whether one-off pieces or larger production volumes.

 Discuss pattern making for your project. Contact Adelaide Brass Castings. Just click here or email admin@abcast.com.au.