HOW IS CAST ALUMINUM PATIO FURNITURE MADE?
Casting is the process by which a material is introduced into a mold while it is liquid, allowed to solidify inside the mold, and then removed, producing a fabricated object. Do you need an example? Jell-O, in effect, is cast into a mold while liquid, producing a wiggly-jiggly object your aunt with the purple hair can bring to Thanksgiving dinner. View Cast Aluminum Patio Furniture From Family Leisure Here.
Cast aluminum patio furniture (Grand Tuscany Dining by Hanamint is pictured right as an example) can be produced through either sand or die casting. Most cast aluminum furniture is sand-cast; not only is it cheaper to produce, it also makes for those delightful imperfections that add to the charm and authenticity of the pieces.
The first step in manufacturing cast aluminum is making a pattern, which is often carved in wood.
A molding box is prepared to receive the pattern. The bottom half of the box is packed with casting sand and the pattern is pressed into the sand. Additional sand is packed on top of the pattern and a lid is attached. The box is turned over, unlatched and the pattern is removed. The box is closed again, and the sand is allowed to dry; this forms the mold.
The box is then filled with molten aluminum alloy and is set aside until the metal is sufficiently cool to be strong. The sand is then removed, revealing a rough casted part. These are sanded, but cast parts will have many imperfections and rough edges, which gives the furniture its hand-crafted, traditional look. The San Marino Cast Aluminum Deep Seating Collection by Veranda Classics is pictured above left as an example.
Each piece of furniture is either welded or bolted together from the various cast parts; most high-end manufacturers of cast aluminum patio furniture smooth and sand the welds for a seamless look.
FUN FACT – The cap of the Washington Monument is cast aluminum.
HOW IS TUBULAR, EXTRUDED OR WROUGHT ALUMINUM FURNITURE MADE?
Wrought, extruded or tubular aluminum patio furniture is very popular because it requires no maintenance, is strong and durable, it won’t rust and it's generally moderately priced. This is the furniture you most often see at resorts and hotels, on cruise ships, beaches and poolside (the Baja Strap Collection from Woodard is pictured right as an example); while tubular patio furniture often has strap or sling seats, you can also find cushioned versions. View Wrought Aluminum Patio Furniture From Family Leisure Here.
The extrusion process is basically a simple one; the best visual of how it works is a Playdough Fun Factory. Just as you push the clay into the plastic “factory” a solid billet or bar of aluminum is pushed through a die. Push the clay through a star-shaped hole, you get a star-shaped tube; push it through a square shaped hole, you get a square shaped tube. The same is true of the aluminum; the billet will form the shape of the die.
High grade aluminum (the Belden Cushion Dining Collection from Woodard is picture left as an example) makes for the best tubing to use in furniture construction; also extrusions that include internal ribbing or reinforcements will result in the most durable, dent and bend-proof extrusions. Extrusions are welded and bolted together to form the final product.
Less common but still available is a rolled aluminum product. Rolled tubing is made by running a flat sheet of aluminum through a series of rollers which form it into a tube. A seam will run the length of the tubing, which makes it inherently weak and easily compromised. Folding “lawn” chairs are often made of rolled aluminum.
FUN FACT – Aluminum is the most abundant element in the earth’s crust!
