Two years ago I wrote a blog post on Sand Casting Medallions. For that project, I already had a master for the medallions that I wanted to cast.
This year, I wanted to cast another dozen medallions for the Kingdom (for a different award) but I had no master. So I thought it might be helpful to document the process of making one. Please note that this process is for sculpting a clay master. There are other ways to make masters, but this is the one I learned.
Here are some of the materials you will need:

- Sculpey brand oven-bake clay (other brands, such as FIMO, work just as well but Sculpey is readily available at almost any store with a craft section)
- Aluminum ring molds or a similar two-piece frame
- Another medallion with the desired thickness for comparison
You can also use this same medallion to outline a circle in your clay. In this case, we actually used the black circle pictured above – it’s a 50mm Warhammer 40k base that served as a cookie cutter for the clay. If you don’t know what 40k is, you’re welcome.
It’s important to remember that the clay master you create must be able to fit inside of your ring molds, so keep those nearby for comparison. I used a 50mm medallion inside a 60mm ring mold, which gave me enough wiggle room inside the mold.
I’d also recommend tools for sculpting clay. There is a 52 piece set available on Amazon here. For this project I used a tiny blade and a dotting tool.
Once you have your materials, break off a chunk of the clay. I started with a piece that I rolled into roughly the size of a ping-pong ball. Once you’ve rolled your clay into a ball, set it on a non-stick surface like wax paper. Then, use a rolling pin (or any other tool with a long, tube-like handle) to roll your clay flat, trying to create as even of a surface as possible.
Once you’ve rolled the clay to your desired thickness, use your circular or cookie cutter type object to form your medallion and remove the excess clay from around the edges.
You can see the clay circle that I created in the picture below on the right. Now is when you can compare the thickness of your clay to your other medallion. I got lucky and managed to roll my clay to the exact thickness that I wanted on the first try!

For this design, I printed off a number of different sized images so I could best match the size to my piece of clay. Once I matched the size of the image to the clay, I cut it out. I then cut out the design itself, so it looked like this:

This will serve as a pattern for the medallion’s design. The next step is to carve out the design from the clay.

I want to note here that again, this is just one way to transfer a pattern to clay. One other method is to trace your design or pattern onto a second piece of flattened clay and then lay it over your medallion shaped clay.
Here is what that looks like:

Both methods work, it really just depends on the style or look you want.
Once you’ve finished carving your clay, you need to bake it according to the package instructions until it hardens. This baked piece of clay will then serve as a rough first draft of your master. Then just follow the usual steps for sand casting, using the clay medallion first.


Once you have that first pewter medallion, you will want to clean up the design so it can serve as your permanent master moving forward. To clean up the medallion, trim the edges with metal snips, files, and a jeweler’s saw to create a smooth outline. For the recessed portions, carve out the design to have a bit more depth with a rotary tool, hand engraver, or files. This part is extremely important and will make for cleaner casts.
A quick side note, clean up is my least favorite part of casting so I usually ask my husband to do that for me. I’m very fortunate to live with someone who has their Laurel in metal working and is willing to teach me casting.

Now you can use your pewter master to cast as many medallions as you need!







