Mold Casting Method
In this method mother letters are first made by engraving letters onto wood. Then casts are made with molding sand and molten metal is poured in the voids to make the metal types.
1 Adhering the letter models to wood
The letter models are adhered to cypress tree wood of a particular size and thickness.
2 Making mother letters
After producing the letter models, the letters are embossed and the letter surfaces are polished.
3 Making the cast
The mother letters are placed face-down in the bottom frame of the cast and pressed into the mold to fill the cast. The top frame is separated and the mother letters are removed to make the type models.
4 Combining the top and bottom frames of the casts
The top and bottom frames of the cast are properly aligned and tightened together to prevent the cast from exploding.
5 Pouring the molten metal
The completed frame is fixed at an angle so that molten metal can flow into it easily. Then 1200 ℃ molten metal is poured into the mold.
6 Polishing the types
When the molten metal has cooled, the top and bottom frames are separated and the branch metals are lifted out. Each of the types on the branch metals are then removed and polished.
To create the typesetting, sufficient space is placed in the middle, then the standard of the fold of the paper and book volumes are put in place, and finally the types are levelled using scrap paper or pieces of bamboo.
The surface of the type is painted with lithographic writing ink, a sheet of hanji (traditional Korean paper made by hand from mulberry trees) is placed on top of it, and the surface is evenly rubbed with a block of brush.
Source: Metal Type Training Center