Charcoal Casting

Jewelry making is usually about control—measuring, cutting, forming, and carefully fitting metal pieces together. Charcoal casting is a little different. Instead of trying to create a perfectly predictable shape, molten metal is poured into a form carved or pressed into a charcoal block. The heat, the shape of the cavity, and the way the metal flows all contribute to the final result.

Casting Directly in Charcoal

Charcoal blocks are probably most familiar to jewelers as a surface for soldering. But charcoal can also serve as a simple casting medium. A shape or texture is created in the charcoal, and metal is heated until it becomes liquid. The molten metal flows into the cavity, cools, and solidifies.

What comes out isn't necessarily smooth or perfect—and it isn't supposed to be. The casting can retain rough surfaces, irregular edges, crevices, and other marks created during the process. Instead of removing all of those characteristics, they become part of the design.

From Rough Casting to Finished Jewelry

The pendant shown here began with a charcoal casting, but the casting was only the starting point. I kept much of the rugged surface and darkened the recessed areas to emphasize the texture. Polished high points catch the light, creating contrast with the darker areas.

I then added granules, a faceted stone, and a pearl, bringing very different surfaces together in a single piece. The result is something that would be difficult to reproduce exactly—even if I tried.

At the Bench

That's what I enjoy about charcoal casting. I can influence what happens, but the molten metal gets a vote too. Sometimes an unexpected ridge, edge, or texture becomes the most interesting part of the finished piece.

Not every imperfection needs to be corrected. Sometimes it's where the design begins.