I recently got to do my first aluminium casting night at the Milwaukee Makerspace. It was kind of a last minute thing by it was really fun.
I ended up carving a shield with the AUA logo on it out of foam. Then I sprued it up and packed it in this special casting sand that reeks like gas. When the aluminum is poured the foam melts away and the sand holds the aluminum in the shape of the mold.
After packing it securely all I had to do was sit back and watch as the professionals took care of the rest. And by professionals I mean the guys with the muscle power big enough to lift the flask full of molten hot aluminum and accurately aim it at the sprues.
The excess aluminum on my piece actually made a cool flaming skull shape!
And the end result is an awesome new dimensional logo for Alchemic Underground!