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An open single-cavity bullet mold and a closed two-cavity mold. A cast bullet is made by allowing molten metal to solidify in a mold.Most cast bullets are made of lead alloyed with tin and antimony; but zinc alloys have been used when lead is scarce, and may be used again in response to concerns about lead toxicity.
Custom lead bullets, such as those for obsolete calibers, wildcat cartridges, or for special purposes, are easily made with inexpensive casting or swaging equipment. In contrast, manufacturing jacketed bullets requires far more expensive equipment to draw the jackets and swage in the core, so is generally limited to commercial projectile producers.
Other advantages of casting or swaging bullets from lead wire (which is pricier but avoids many quality-control issues of casting) is the ability to precisely control many attributes of the resulting bullet. Custom bullet molds are available from a number of sources, allowing the handloader to pick the exact weight, shape, and diameter of the ...
Hand-cast bullets allow the shooter to optimize the alloy for strength and expansion at the higher velocities generated by the Marlin over the traditional .44 caliber bullets. There are several commercial molds available for the hand-caster: the SAECO No. 433 mold, which casts a 300-grain (19 g) gas-checked bullet, and the Lyman 429640 at 280 ...
Permanent mold casting. Permanent mold casting is a metal casting process that employs reusable molds ("permanent molds"), usually made from metal. The most common process uses gravity to fill the mold, however gas pressure or a vacuum are also used. A variation on the typical gravity casting process, called slush casting, produces
The mold is formed around this chemise by covering it with loam. This is then baked (fired) and the chemise removed. The mold is then stood upright in a pit in front of the furnace for the molten metal to be poured. Afterwards the mold is broken off. Molds can thus only be used once, so that other methods are preferred for most purposes.
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The other common manufacturing method is casting, which uses molten metals poured into a mold. Since metals expand when heated and contract when cooled, cast bullets must be cast with a mold slightly larger than the desired finish size, so that as the molten metal cools, it will harden at just the right point to shrink to the desired size.
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