How to Cast Aluminum in Plaster

Written by sanne godfrey
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How to Cast Aluminum in Plaster
Aluminium keychains can be cast in plaster. (golden metal sun image by Alex Dascalu from

Casting aluminium in plaster is a very simple process that can be done from home if needed. The process of casting a metal in plaster can be done for many of the metals with a low melting temperature, such as copper, magnesium and zinc. The plaster cast will only be good for one-time usage, because it is broken to reveal the aluminium. So, if you intend to use it more than once, you will need to make several moulds.

Skill level:

Things you need

  • Talc
  • Sand
  • Sodium silicate
  • Spray bottle
  • Molten aluminium
  • Brass pattern halves

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  1. 1

    Mix the plaster with talc, sand, sodium silicate and water to form a liquid substance.

  2. 2

    Pour the liquid into a spray bottle and spray the mixture on polished brass pattern halves. The liquid needs to be at least 1.5mm thick to form a sturdy mould.

  3. 3

    Dry the liquid for about 15 minutes in the mould. After this, extract the mould and dry it in the oven for 30 minutes at a temperature of 54.4 to 65.6 degrees Celsius.

  4. 4

    Pour the molten aluminium in the plaster moulds.

  5. 5

    Break the plaster moulds and wash the aluminium to remove any signs of the plaster casing.

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