Is there a better way to mold aluminium into tableware than using green sand molds?
Die-press from flat stock. Steel injection molds should work. Lost wax with modified plaster molds.
If you look into old pewter molds, you MIGHT be able to make a two part pour mold out of high temp materiel-bearing in mind that anything easy to mold is going to fall apart quickly.
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Spinning, diecasting, lost wax, billet machined, pressed. Sand casting will be horribly porous and the metal brittle.
Thought, you could make a two part mold of the silverware in clay or rubber, then take investment/modified plaster casts to duplicate the molds and use them as waste molds with maybe a few casts each before they start eroding.
DO NOT just use plaster-the water in it has to have a way to escape or it will crack or explode when the aluminum hits it. Fine sand (50:50) added has been said to work, investment IF burnt out should work but is very soft.