Visit to our foundry

Pouring metals for hardware manufacturer[tweetmeme source=”@SABaxterLL” only_single=false http://www.URL.com%5D While SA Baxter, manufacturer of custom and semi-custom architectural hardware, has earned an international reputation for excellence and has completed projects in Russia, Europe, the Middle East, India and South America, the company still creates all of its architectural hardware and architectural metals in it’s Upstate NY foundry and atelier for end-to-end, in-house, in the US.

All SA Baxter hardware are manufactured using a lost-wax casting approach that dates back to Ancient Egypt. This method, in conjunction with the latest in CAD/CAM modeling and prototyping technology, allows SA Baxter to produce highly detailed and customized hardware designs that other companies do not have the capacity to create.

To create an SA Baxter door knob, door pull, door lever, window lever or hinge, a mold is created from either a CAD-generated 3-D model or hand-carved original form. This mold is then injected with wax, which is carefully hand-worked to remove any parting lines or defects.

Door knob cast for hardware manufacturing

Door knob casts

The fully-formed wax mold then goes through a complex process of heating and melting until the wax is completely melted, or “lost,” and replaced with molten metal by SA Baxter’s experienced foundry craftsmen. The end product is an exact metal version of the original carving or 3-D model.

This product is then put on CNC-programmed lathes and mills, where the mechanical interface is precision-cut for perfect fit and operation. After precision-cutting the product is inspected and finished with one of 200 possible finishes that are meticulously and repeatedly applied over several days of hand polishing, texturing, hammering, chasing and plating.

Watch the video of our architectural hardware manufacturing process, mixing lost-wax casting with the latest in computer aided design and be sure to subscribe to our channel:


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