Safety & Ethics

Molten metal is no joke. Safety is mandatory. Always.

Important Safety Notice

Metalcasting involves extreme temperatures, toxic fumes, molten metal, and serious injury risk. This page is informational only and does not replace proper training, supervision, and professional guidance. If you're new to casting, seek in-person instruction from experienced foundry operators. Melt Make assumes no liability for injuries or damages resulting from metalcasting activities.

Non-Negotiable Safety Requirements

These are the minimum safety standards we follow in every project. No exceptions.

Personal Protective Equipment (PPE)

Required for every pour:

  • Face shield (not just safety glasses)
  • Leather gloves (welding-grade, full gauntlet)
  • Leather apron or foundry suit
  • Closed-toe boots (leather, no synthetic)
  • Long pants (cotton or denim, no synthetics)
  • Long-sleeve shirt (natural fibers only)
  • Respirator when handling zinc-bearing alloys

Ventilation

Fume control is mandatory:

  • Outdoor casting preferred
  • Indoor: exhaust hood or high-CFM fan
  • Never cast in enclosed spaces
  • Respirator with appropriate filters for zinc/lead
  • Monitor air quality if indoors
  • Zinc oxide fumes are toxic—avoid at all costs

Fire Safety

Fire prevention and response:

  • Fire extinguisher (ABC or Class D) within reach
  • Clear 10-foot radius around furnace
  • No flammable materials in work area
  • Sand bucket for emergency containment
  • Know your escape route
  • Never pour on wet or damp surfaces

Moisture Hazards

Moisture + molten metal = explosion:

  • Pre-heat all tools, crucibles, molds
  • Never pour on wet concrete or surfaces
  • Inspect materials for trapped water/oil
  • Dry sand thoroughly before molding
  • Store ingots/materials in dry location
  • Check for ice/snow in outdoor work areas

Know Your Alloys: Toxic Materials

Not all materials are safe to melt. Some alloys release deadly fumes.

High-Risk Alloys

Zinc (galvanized steel, die-cast parts):

Releases zinc oxide fumes (metal fume fever). Symptoms: flu-like illness, fever, chills. Respirator mandatory. Galvanized steel = zinc coating.

Lead (wheel weights, old plumbing, solder):

Extremely toxic. Accumulates in body. Causes neurological damage. We do not cast lead at Melt Make. Respirator + HEPA filtration required if unavoidable.

Cadmium (some brazing rods, electroplating):

Highly toxic fumes. Can cause kidney damage and cancer. Avoid completely.

Beryllium copper (aerospace, electronics):

Beryllium oxide fumes are extremely hazardous. Only cast in controlled industrial settings with proper ventilation and monitoring.

Safer Alloys (with proper PPE)

Aluminum (wheels, cans, extrusions):

Relatively safe if clean. Watch for coatings/paint. Avoid magnesium alloys (fire hazard). Test with file—soft = likely aluminum.

Brass (keys, fittings, decorative items):

Copper + zinc. Zinc fumes still a concern—good ventilation required. Avoid high-zinc brasses (yellow brass). Red brass is safer.

Bronze (bearings, marine hardware, statues):

Copper + tin. Generally safe with standard PPE. Watch for leaded bronze (machinability grade)—contains lead.

Copper (wire, pipe, radiators):

Pure copper is safe. High melting point (1085°C). Remove insulation outdoors (burning insulation = toxic fumes).

Ethics & Legal Sourcing

Not all materials are legal or ethical to melt. Know the rules.

Never Melt These:

  • ✗Currency (coins, bills) — Federal crime in most countries
  • ✗Catalytic converters — Often stolen; legal issues
  • ✗Stolen materials — Know your source; get receipts
  • ✗Historic artifacts — Irreplaceable cultural items
  • ✗Radioactive materials — Some old items contain radium/thorium

Good Material Sources:

  • ✓Recycling yards (commercial, documented sources)
  • ✓Thrift stores (brass, copper decorative items)
  • ✓Auto recyclers (wheels, radiators with documentation)
  • ✓Your own materials (broken tools, failed projects)
  • ✓Curbside finds (with permission, clear ownership)

Product Safety & Use Limits

No food-contact items: We do not make or sell cookware, utensils, or any food-contact products. Hobby casting does not meet food-safety standards.

Load limits: All structural parts (cleats, pulls, knobs) are tested and include load ratings. Do not exceed published limits.

Inspect before use: Check for cracks, porosity, or defects. If damaged, discontinue use.

Marine hardware: Brass and bronze parts are suitable for marine use but should be inspected regularly for corrosion.

Disclaimer: This page is for informational purposes only. Metalcasting is inherently dangerous. Melt Make is not responsible for injuries, property damage, or health issues resulting from metalcasting activities. Seek professional training and follow all local regulations.

Last updated: October 2025