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KBC Jewelry  
Wholesale Silver Jewelry and Silver Beads
CUSTOM STERLING SILVER JEWELRY
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Casting Production Process

Designing to mastering process

Molding to casting production process

Unfinished to finish products:
- High-end finishing for plain silver jewelry
- High-end finishing silver with gemestones
- Tumble finishing

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The silver jewelry casting and production process’s that are explained here are the basic ideas of how we run our production at KBC Jewelry. This gives you the basic idea of how silver jewelry is cast and finished. There are many variables involved and the actual process is much more complicated than it may appear here.

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Hand Made Production Process

View photos of how our traditional craftsmen work to make silver jewelry:
- Melting silver to make silver ingot
- Silver forming to make silver sheet
- Silver forming to make silver wire

In Indonesia, all hand made silver jewelry starts from a silver ingot, which is then formed into silver sheet and wire as required for the silver jewelry that is being made.

Silver sheet is used for making bezels and forming shapes etc. Silver wire is used for making ornamental designs on the silver sheet and making Bali jawan etc.

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Molding to Casting Production Process
 


Pictures 1 Molding

A perfect master or prototype is a must for making a rubber mold. The prototype is vulcanized in uncured rubber, which is then cut apart to create the production mold. There is normally a slight shrinkage of 3-5% from the original prototype to the wax pattern that will come out of this mold. The rubber mold will normally produce from 500 to 1000 wax patterns before showing signs of wear.

Picture 2 Wax pattern production

A wax injector is used to fill the rubber mold with wax, which is then carefully removed after hardening. After touching up the wax patterns they are attached to a 1/2-inch diameter wax rod forming what is called a tree.

Pictures 3, 4 - 5 Casting process

The wax tree is then inserted into a capped steel flask and a special type of plaster called “investment” is poured into the flask to fill it. Once the investment sets the cap is removed and the flask is placed into a burnout oven, or kiln, where the wax is melted out to leave a cavity in the investment exactly the shape of the wax tree. The flask is placed in a high tech casting machine (picture 4) and molten silver is injected into the mold cavity. After the molten silver solidifies the investment is removed using a high-pressure spray gun. We see the cleaned silver trees in picture 6.

Same as Designing to Mastering Process

Pictures 6 - 7 Cutting and grinding

The individual pieces are clipped from the tree using diagonal cutters designed specially for this purpose. The remaining bit of the sprue is ground off using a cratex grinding wheel.

Picture 8 Unfinished product

 

Satisfaction guaranted Silver Content Guaranteed
A minimum Silver content of 92.5% guaranteed in all of our cast Silver Jewelry products legally defines them as Sterling Silver Jewelry and assures our customers of the best quality. Our Silver Jewelry contains no metals that cause allergic reactions.
 
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