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July 7, 2020

Metal Craft News

Aluminium Casting a Relief Wall

Kikukawa provides various metal constructions and metalwork, including those requiring casting.

Casting, a process of moulding liquid metal into the intended shape, is best suited for large-lot productions, or designs with complex shapes and details that are difficult to achieve with bending.

By combining Kikukawa’s expertise and in collaboration with related companies, Kikukawa provides bespoke casting for various metals and finishes.

Here is an example – a project with aluminium casting completed in 2015, a relief wall for the living quarters of a temple in Tokyo.
The aluminium casting achieved a stately bespoke wall of lotus flowers, a Buddhist symbolism.

The temple wall and the living quarters. The left building is covered in the aluminium relief wall fabricated from casting
The temple gate and the living quarters. The left building is covered in the aluminium relief wall fabricated from casting
The lotus flower relief wall is 4900mm wide, and 7350mm high
The lotus flower relief wall is 4900mm wide, and 7350mm high

The relief wall of roughly 36㎡ , was created from a single 350mm by 350mm square aluminium casting. Nine castings were combined into a 3 by 3 square to create the standard pattern. To create diversity in design, a number of the castings were turned over or rotated. Each was then finished with fluoro-resin paint coating.

Left: Sample lotus flower casting. Right: The standard pattern of casting placed together
Left: Sample lotus flower casting. Right: The standard pattern of casting placed together
At both ends, 3x3 castings are placed. The center is lined with 2x4 casting.
At both ends, 3×3 patterns are placed. The center is lined with 2×4 patterns.

The difficulty in this casting stems from the sharp edges of the flowers, a challenge overcome by various fabrication tests and modifications. Kikukawa’s expertise ensured the quality of the casting, as well as the fixing details that achieve both strength and transparency.
To further ensure the quality of the product, Kikukawa assembled the products within the factory to understand the final adjustment necessary.

The QC inspection
The QC inspection

As the client was very pleased with this lotus flower relief wall, additional casting relief walls were adopted for other areas of this project.

In addition to the project listed above, Kikukawa has experience in casting other metals. This, in combination with other metalwork, allows us to provide the best-suited metalwork solution in price and quality for metal constructions.
Kikukawa also has extensive experience in religious architecture with complex designs and those requiring precision.

Please do not hesitate to contact us for feasibility or consultation.

Click here to learn more about Kikukawa’s religious architecture