How to Make Metal Sculpture Without Welding

Making metal sculptures without welding can be a fun and challenging process. However, there are many ways to make metal sculptures without using a welder, and in this blog post, we will explore some of those methods on how to make metal sculpture without welding.

How to Make Metal Sculpture Without Welding

Whether you’re an experienced sculptor or just starting, we hope these techniques will help you create beautiful metal art pieces. Making metal sculptures without welding can be challenging, but it is possible. So whether you’re a beginner or an experienced sculptor, there’s something for everyone here. So, let’s get started!

What Is Cast Sculpture

Cast sculpture is any metal art that has been removed from its parent material, either through carving or using a mold. Once the cast sculpture has dried, it is usually painted with enamel, lacquered, or given an epoxy coating to protect it against weathering.

When you think about making metal sculptures without welding, the cast sculpture is probably what you had in mind. For cast metal sculptures, this process begins with the sculpture made in wax, which will later be replaced with some other material, like metal. Depending on the type of metal you use, a process called cold casting may be used.

Tools and Materials Needed

  • Needle-nose pliers.
  • Wire cutters.
  • A metal file or coarse sandpaper to smooth out edges if necessary.
  • A hammer (optional).
  • A piece of wood or metal to pound on.
A Piece of Wood or Metal
  • Wire (optional).

Introduction: How to Make Metal Sculpture Without Welding

Step 1: Designing Your Piece

An excellent place to start is with a sketch. It doesn’t have to be unique, but you should at least note where the welds need to go and how that relates to the symmetry of your piece. Then add your design elements on top of the sketch to visualize what it will look like in three-dimensional space. For example, if you are making a face, sketch the basic shape first. Then add the features.

Step 2: Fabricating Your Piece

Now it’s time to create your design elements. Again, you can use any material you want for this, and I would recommend using pre-existing pieces if possible so that you don’t have to worry about welding.

For example, old bed frames work great as sculpture skeletons because they already have holes for welding, are easily bent into shapes, and come in various sizes. However, if you want to create your pieces, it is best to use a plasma cutter or gas torch. The latter option will require more skill, but the finished product will be of higher quality and less expensive.

Step 3: Making the Mold

When you are finished with your piece, it is time to make the mold. You can use spray foam insulation for this, and I recommend getting the kind that expands when you add a chemical. Just spray it in the shape of your piece onto your workbench, let it cure for about 10 minutes, then pop it off.

Step 4: Casting Your Piece

Use a fiberglass resin to cast your piece. Then, all you have to do is pour it into the mold and wait for it to harden. I recommend putting a small scrap inside the mold to avoid having to worry about orientation. If you are worried about your piece falling over in the mold, you can use wooden dowels to prop it up.

Use a Fiberglass

Step 5: Filling Seams

Now that you have cast your piece, all left is to fill the seams where pieces meet. Use a two-part epoxy for this. Pour it into the seams and let it dry. Once it has dried, sand it down until the seams are flush.

Step 6: Casting the Metal Parts

There are several ways to go about this. First, if you have access to a metal shop, they can cast your piece for you using sand casting or lost-wax techniques. If you don’t, it is best to cut out the shapes for your metal pieces using sheet metal. However, if adventurous enough, you could always melt down old car parts and cast them to your specifications.

Step 7: Grinding the Metal Parts

Take all of your metal pieces and grind off any unnecessary bits. To cast the metal parts, you will need a pressure pot. Pour resin into your mold and let it cure. Then place aluminum scrap in the pressure pot, fill it with sand, and put your mold on top of it. The sand will protect the resin from exposure to high pressures while still providing enough pressure to force the liquid metal inside the mold.

Step 8: The Finished Piece

Finally, after all of that hard work, you will see your finished piece shining in the light! All that is left to do now is weld it together and mount it on a base. Again, congratulations! You have successfully created metal sculptures without welding.

You Can Check It Out To Identify Bronze Sculpture

Some Tips and Suggestions

Here are some tips and suggestions on how to make metal sculpture without welding.

1. Using magnets or other devices to hold your piece in place while you make the welding fine adjustments.

2. Using a rolling mill (small hand-operated roller) and steel bar to roll and fold cold metal sheets over each other, rather than bend it with hammers and torches like blacksmiths of old.

Using a Rolling Mill

3. You can use a mig welder or arc welding to bond metal pieces together, but I find that they are not the best solution. There are different types of metal (carbon, alloy, stainless steel), and you might not be able to weld all the types together.

4. You might need some skills/knowledge of welding/metalworking for this, but if you have a little bit, that is perfect!

5. Try making a design of your own, maybe something different from the usual metal art.

6. You don’t have to buy expensive tools; some simple household items or cheap implements can be used for the same purpose.

7. If it is your first time working with metal, you might think of doing small projects before starting your big one.

How Do You Melt Metal Together

Metal sculptors melt metal by using torches, sticks, and electrodes. A gas welding torch is an easy way to start melting metals together. Direct current (DC) allows artists to move the arc to any point on a metal surface as it is always centered between the electrode and the workpiece. The only drawback of DC is that high amounts of current are needed to create enough heat for welding.

Gas welding torches give off a high-intensity flame that can reach up to 50,000 degrees Fahrenheit (27,760 degrees Celsius). The metal only melts once it reaches a temperature of 2,600 degrees Fahrenheit (1,540 degrees Celsius). Arc welding is an excellent way to join two pieces of metal together.

A stick electrode or a wire electrode can be used as a substitute for a gas welding torch. First, the electrodes are connected to the power supply. Then, the welded material is attached to an electrode holder, which provides the electrical path from the power supply to the workpiece.

Is Super Glue Good for Metal

Most metals have a surface that is an oxide layer, and the glue just doesn’t bond to this as well as it does with most plastics or woods. So instead of being permanently bonded to the surface, it sticks only until the surfaces are pulled apart.

The key for welding would be a cyanoacrylate glue, which melts the surfaces together. However, suppose you are trying to stick two metal pieces of uniform size. In that case, it is possible to clamp them together with an appropriately sized piece of wood or plastic in between the metal plates and use epoxy instead of super glue.

What Can I Use Instead of Welding

For some things, there is no alternative to welding. Structural steel beams must be welded together, for example. However, many metal sculptures are intended merely to decorate or delight and do not need to withstand great stress.

If you want to make something like this without welding, you have many possibilities. First of all, use duct tape. Please don’t be ashamed, and it’s ok to use duct tape for things that are not ducts.

Use Duct Tape

You can use it to hold pieces of metal together temporarily to carry them somewhere or move them into a place where you want to weld them. Or hold them together with weights while the glue dries if they don’t need a more convenient position, for example. The adhesive on duct tape never weakens with time and temperature, so your hold will stay firm until you make a better arrangement.


The process of metal sculpture without welding is a difficult but rewarding one. It can be frustrating, as it takes time to learn the intricacies and nuances that go into this craft, but don’t’ give up! You will find your work brings you both joy and pride when done correctly with patience and determination.

We have provided you with some helpful tips on how to make metal sculpture without welding, so hopefully, this help gets you started in the right direction.

If not, please reach out for more information from our team of experts who are ready and waiting to partner with you in making beautiful art pieces made from steel or aluminum sheeting at affordable prices. What questions do you still have about this process? Let us know in the comments below!

Jennifer Branett
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