Beskar Mezuzah

I've always been fascinated by metal casting, and I finally conceived a project involving pewter casting, which can be easily accomplished at home with minimal special tools.

Inspired by a prop from The Mandalorian series, I created pewter mezuzahs featuring an organic Damascus steel pattern.

3D printing continues to be a versatile force multiplier for me. In this project, although the final product is not printed, 3D printing served as a crucial intermediate step, enabling me to progress from idea to digital design to finished product in just a matter of weeks.

Tools Used: SolidWorks, 3D Printing, Pewter Casting Beskar Steel Beskar Steel

The inspiration for this project is the beskar steel prop from the Mandalorian series. CAD Model CAD Model

Creating the pattern was an interesting challenge, not only to make it look organic but add the right 3D depth. I ended up using a manipulated image of Damascus steel and the 3D texture tool in SolidWorks 2019 3D Print 3D Print

I sent the finished design to an Etsy seller that printed it in high resolution digital resin. The print took a little cleanup and manual engraving to get the finish I was looking for. Silicone Mold Silicone Mold

Using the 3D print as a master I created a mold using high temperature silicone, MoldMax 60 from Smooth-on.

I hand carved the feed and air vent holes into the mold. Raw Casting Raw Casting

The mezuzahs were cast with pewter which is easy to work with in a home environment. Each cast took a little post-processing: drilling the nail holes and removing the sprue.. Finished Mezuzahs Finished Mezuzahs

To get more depth out of pattern I applied black wash then sanded back the high spots. The finished pieces have a nice heft and look great, I am very excited to do more metal casting in the future.