The Workshop
Our workshop is the heart of Anglia Sign Casting, and it is where our small team spends each day shaping raw metal into something meaningful for our customers.
Moulding is the first real step in turning an idea into a cast plaque. We begin by preparing the pattern, which is usually a wooden prototype of the final piece. This is placed into a special sand mixture that we pack by hand using simple ramming tools. It is important that the sand is rammed firm enough to hold fine detail, and getting this right is something that only comes with experience.
Pouring the metal is one of the most important stages of the process. Once the mould is prepared, we melt the metal in the furnace until it reaches the right temperature for casting. When it is ready, we lift the crucible from the furnace and pour the molten metal slowly and steadily into the mould. It is a moment that always requires focus, but it is also one of the most satisfying, as this is when the plaque truly begins to take shape. After the pour, we leave the metal to cool naturally.
Fettling is the stage where the casting is cleaned up and brought closer to its final finish. Once the metal has cooled, we break open the mould and lift out the raw plaque. It always comes out with excess metal and a rough surface, so we use a mix of hand tools and grinders to remove the runners, smooth the edges and take away any imperfections left from the casting.
After the plaque has been fettled and prepared, we move on to the finishing stage, where the character of the piece really comes to life. Many of our plaques are powder-coated, which gives them a tough, even finish that protects the metal and provides a clean background for the raised lettering.
For customers who prefer a more traditional look, we also offer hand-applied patination. This ages the plaque for an antique look, and once the recessed areas have taken on the patina, we linish the raised details so the lettering stands out with a soft, natural contrast. Whether it is a modern powder-coated finish or a classic patinated look, this stage is all about giving each plaque the finish that suits it best.
Behind every plaque we make is our small workshop team: Kevin, Steve and Nath. Each of them plays a hands-on role in the process, from preparing moulds to pouring metal, fettling castings and adding the final finishes. They all bring their own experience and approach to the job, but they work closely together and keep a careful eye on every detail that passes through the workshop. It is a genuine team effort, and it means every plaque is made with care from start to finish.