Press Aluminum Cans into Ceiling and Wall Tiles

Step 5 Clean up the cast

Use a wire brush, grinder, file, and dremel to clean up the cast. Remove little bumps and funny spots and cut the sprues off the casts. If you used styrofoam egg carton for the mold details, the depth of the positive die needs to be taken down by about half; also round the all the edges slightly. This might take a while until both casts fit together nicely with wiggle room. If there is too little wiggle room between the negative and positive die, it can act like scissors and cut or break the thin aluminum tile.