Copyright Apollo Casket LLC. All Rights Reserved.
Apollo Casket LLC
(612) 237-6022
(612) 237-6022
| 2524 PILLSBURY AVENUE SOUTH MINNEAPOLIS, MN 55404 (612) 237-6022 info@apollocasket.com |
| THE PROCESS OF MAKING AN APOLLO CASKET |
Each casket is unique because they are handmade. There are many hands-on
applications at various stages in the production process from start to finish.
To begin with, each model is hand-carved in clay. The clay model is then cast in
aluminum at a foundry, using the centuries old sand-casting process. The sand in
this case is finely ground silica to capture the fine details. Each casting, called a tool,
is about the size of a station wagon and weighs about one thousand pounds. The
tool for each lid is two parts, and for each base is three parts. The parts are
clamped together in a complex way to allow access for hardware such as the casket
handles. Aluminum is melted in a large cauldron, until it is a bright, shiny, silver
liquid. It is then slowly hand poured into the sand mold, as six people hold wooden
plugs shaped like bowling pins to control the flow. This precise control eliminates
air pockets and allows for proper cooling among other things. The tool is finished
and is ready for the production plant.
At the production plant, the caskets are made by a process called rotational molding.
The tools, or molds, are opened and filled with a hand-mixed resin pigmented with
bronze and gold, or alabaster marble. After they are filled, the tools are clamped
shut, attached to a mechanical arm which spins the tool in a huge oven. The resin
melts inside the tool and forms the casket. This is a very precise and complex
procedure involving timing and flexible temperatures at various stages including a
gradual cooling process. After cooling, the tool is opened up, revealing the molded
part. This molded part is then "flamed", that is to say, an artisan applies an open
flame over the gold metals to burnish it and create the gold patina. Lastly, the
bedding is laid inside and arranged complete with lavender sachet. The casket is
boxed and sent off with care and love.
applications at various stages in the production process from start to finish.
To begin with, each model is hand-carved in clay. The clay model is then cast in
aluminum at a foundry, using the centuries old sand-casting process. The sand in
this case is finely ground silica to capture the fine details. Each casting, called a tool,
is about the size of a station wagon and weighs about one thousand pounds. The
tool for each lid is two parts, and for each base is three parts. The parts are
clamped together in a complex way to allow access for hardware such as the casket
handles. Aluminum is melted in a large cauldron, until it is a bright, shiny, silver
liquid. It is then slowly hand poured into the sand mold, as six people hold wooden
plugs shaped like bowling pins to control the flow. This precise control eliminates
air pockets and allows for proper cooling among other things. The tool is finished
and is ready for the production plant.
At the production plant, the caskets are made by a process called rotational molding.
The tools, or molds, are opened and filled with a hand-mixed resin pigmented with
bronze and gold, or alabaster marble. After they are filled, the tools are clamped
shut, attached to a mechanical arm which spins the tool in a huge oven. The resin
melts inside the tool and forms the casket. This is a very precise and complex
procedure involving timing and flexible temperatures at various stages including a
gradual cooling process. After cooling, the tool is opened up, revealing the molded
part. This molded part is then "flamed", that is to say, an artisan applies an open
flame over the gold metals to burnish it and create the gold patina. Lastly, the
bedding is laid inside and arranged complete with lavender sachet. The casket is
boxed and sent off with care and love.
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