🥉 Bronze Pins – Lost-wax casting

🔹 Context

This project started from a simple need: creating custom pins for a student association using their logo. The goal was to design a durable metal object with a premium finish. I decided to create bronze pins using the lost-wax casting process, handling every step from modeling to the final casting.

🛠 Manufacturing steps

✔ Digital preparation

- Vectorized the logo PNG using Illustrator to create a multi-layer SVG
- 3D modeling in Creo with varied extrusions for different logo depths
- Added a pin post with a locking bulge to ensure good grip with the clasp
- Designed a 20-pin tree spread across 2 levels, optimized for material saving and resin flow

✔ Mold fabrication

- 3D printed the tree using castable resin
- Carefully removed supports and cleaned surfaces
- Embedded the tree in plaster following technician-recommended ratios
- Controlled heat treatment to burn out the resin and fully dry the mold

✔ Casting and finishing

- Bronze melted by induction heating in argon atmosphere
- Vacuum casting into the mold
- Water quenching to break the plaster and reveal the pin tree
- Cut and separated each pin using a Dremel, followed by sanding
- Selective polishing to highlight the raised parts of the logo

💬 Personal note

This project was a real pleasure to carry out. I received support from the workshop team at every stage, and their enthusiasm helped turn a personal idea into a high-quality, tangible result.
It was especially satisfying to go from a 2D logo to a polished bronze object, and to go through the full cycle from digital modeling to metal casting.
Beyond the technical aspects, it’s great to know that this process is now documented and ready to be reused by future members of the association.

📌 What's next?

Future members of the association can now easily launch new production runs using the model I created. The project is now a turnkey process.

🧰 Skills applied

Graphic vectorization (Illustrator), Advanced CAD (Creo), Resin print optimization, Foundry and metal casting techniques, Lost-wax molding, Castable resin handling, Manual post-processing, Precision polishing

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