Lesson Plan: Sand Mold Carving & Aluminum Casting

Grade: 3-5
Duration: 2 weeks, 4 sessions (~1.5 hours each)

Lesson Overview

Students learn about reductive carving in sand molds used for metal casting. They design, carve, prepare molds, and observe a supervised aluminum pour, emphasizing artistic process, STEM concepts, safety, and teamwork.

Week 1

Class 1: Introduction & Design Planning

Activities:

• Introduce metal casting and sand molds (videos, images)
• Discuss safety procedures and teamwork
• Brainstorm and sketch design ideas

Standards Addressed:

• NY State Arts: Creating and designing art processes; understanding materials
• STEAM: Engineering design, understanding of physical properties, safety awareness

Class 2: Building & Initial Carving

Activities:

• Build base mold in sand
• Carve shape following sketches, removing material carefully
• Stabilize mold with water spray
• Document progress with photos

Standards Addressed:

• NY State Arts: Use of tools, craftsmanship
• STEAM: Application of engineering and science concepts; investigation and experimentation

Week 2

Class 3: Refinement & Preparation

Activities:

• Finalize carving, adding detail
• Review safety for aluminum pouring
• Prepare molds for pouring

Standards Addressed:

• NY State Arts: Refining art through practice
• STEAM: Science of heat and materials; engineering of mold design

Class 4: Aluminum Pouring & Reflection

Activities:

• Supervised pouring of aluminum into molds
• Post-pour safety review and cleanup
• Reflection and discussion of the process, teamwork, and interdisciplinary concepts

Standards Addressed:

• NY State Arts: Art reflection, process understanding
• STEAM: Understanding scientific principles behind metals and heat; collaboration and problem-solving

Cross-Curricular Connections

• Science: Properties of metals and sand
• Math: Measuring and planning designs
• History: Ancient metalworking techniques

Assessment

• Participation and teamwork
• Quality and creativity of carved molds
• Understanding of reductive carving process
• Reflection on learning and safety