ForgeBorn Casting Co.
Charlotte, NC • Precious Metal Casting

Cast in Silver
& Gold

3D printed resin casting — from your digital file to finished precious metal

Shop Collections Upload Your STL
Sterling .925
Fine .999
14K / 18K Gold
Rose Gold
Bronze
Pewter
Brass
Aluminum
“
Bring us your .STL file. Bring us a napkin sketch. Bring us a broken heirloom. We’ll cast it.
The Payton Family
ForgeBorn Casting Co. • Charlotte, NC
About
ForgeBorn Casting Co.

Based in Charlotte, North Carolina. ForgeBorn is a full-service metal casting studio in Charlotte specializing in sterling silver, bronze, and gold. We combine high-resolution resin 3D printing with vacuum and sand casting to bring digital designs to life in real metal.

We serve independent jewelers, tabletop game designers, artists, collectors, and makers. Whether you need a single custom ring or a production run of 500 gaming miniatures, our studio handles everything — file to finished metal.

Your design. Our craft. Precious metal.

8
Metals Offered
25Ξm
Print Resolution
5
Day Turnaround
CLT
Charlotte, NC
Services
Your File. Our Forge.
Metal casting for everyone — not just jewelers. Local to Charlotte, serving makers, businesses, and creators nationwide.
ðŸ”Ĩ
Metal Casting
3D printed resin burnout with vacuum and sand casting. Plaster investment. Single pieces to production runs in 8 metals.
  • Sterling, Fine Silver, Gold
  • Bronze, Brass, Pewter, Aluminum
  • Vacuum casting & sand casting
  • 1 piece to 500+ production runs
⚙ïļ
Custom Parts & Prototypes
Replacement parts, prototype-to-metal, small-batch manufacturing. If you can model it or describe it, we can cast it in metal.
  • Vintage car & motorcycle parts
  • Architectural & decorative hardware
  • Broken part reproduction
  • Engineer & inventor prototypes
  • Small-batch manufacturing runs
🏠
Local Charlotte Services
Walk-in consultations, same-week turnaround on rush jobs, and local pickup. No shipping needed — we're in your backyard.
  • In-person consultations
  • Local pickup available
  • Rush jobs & same-week turnaround
  • Charlotte maker community partner
  • UNC Charlotte & art school collabs
ðŸ–Ļïļ
3D Printing & Resin Service
High-res resin printing for castable masters, visual prototypes, or finished resin pieces. No casting required.
  • Castable resin for metal burnout
  • Standard resin prototypes
  • .STL .OBJ .GOO .3DM accepted
  • 25-50 micron layer resolution
ðŸŽĻ
Art & Sculpture Reproduction
Turn your sculpture, model, or digital art into bronze, silver, or aluminum. Editions, trophies, awards, and display pieces.
  • Sculptor edition runs
  • Custom trophies & awards
  • Memorial & tribute pieces
  • Gallery-quality finishing
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Finishing & Polish
Raw casting to retail-ready. Tumble, hand polish, patina, plating, and assembly.
  • Mirror or satin brush finish
  • Antiqued / oxidized patina
  • Gold plating over sterling
  • Stone setting & assembly
📐
Mold Making
Silicone and plaster molds from your master or our print. Reproduce your design at scale.
  • Plaster investment molds
  • RTV silicone molds
  • Sand casting molds
  • Mold storage & reorder
ðŸĪ
Contract & Wholesale Casting
Wholesale casting for jewelers, designers, game companies. NDA available. Your designs stay your IP.
  • White-label production
  • Confidential NDA protection
  • Volume & repeat discounts
  • Dedicated account manager
Flagship Piece
The Sovereign Chess Set
50 troy ounces of sterling silver. Gold-plated vs. polished silver. An heirloom forged to last generations.
Gold Plated Side
♚ ♛ ♜ ♝
♞ ♟ ♟ ♟
Polished Silver Side
♔ ♕ ♖ ♗
♘ ♙ ♙ ♙
Limited Edition • Made to Order
50oz Sterling Silver
Chess Set
Modified Staunton — 32 solid cast pieces
  • 50 troy ounces .925 sterling silver total
  • 16 pieces 24K gold plated (one side)
  • 16 pieces high-polish mirror silver (opposing)
  • King: 3.5" tall, 95g solid sterling
  • Queen: 3.1" / Rook: 2.2" / Bishop: 2.7"
  • Knight: 2.4" sculpted horse head, highest detail
  • 16 Pawns: 1.75" each, 32.5g solid
  • Green felt bases, weighted for play
  • Custom walnut presentation box included
Starting At
$17,800 USD
Metal priced at day-of-order spot • ~$4,362 intrinsic silver value at current spot
Commission This Set
Weight Distribution — 32 Pieces
♚
King × 2
95.0g each
3.05 ozt / 3.5"
♛
Queen × 2
82.0g each
2.64 ozt / 3.1"
♜
Rook × 4
62.0g each
1.99 ozt / 2.2"
♝
Bishop × 4
52.0g each
1.67 ozt / 2.7"
♞
Knight × 4
56.0g each
1.80 ozt / 2.4"
♟
Pawn × 16
32.5g each
1.04 ozt / 1.75"
Total: 1,554g • 49.97 Troy Ounces Each side: 777g (25 ozt)
Flagship Piece
The American Landscape
100 troy ounces of .999 fine silver. 50 states, each a puzzle piece. 3D topographical detail you can feel. Displayed in a handcrafted walnut table under glass.
100oz Fine Silver USA Puzzle Map - 50 State Jigsaw with 3D Topographical Detail
50 Interlocking States • 3D Topographical Relief
Shown with optional birthstone markers & gold plating
Heirloom Commission • Made to Order • 8–12 Week Lead
100oz Fine Silver
USA Puzzle Map
3D Topographical Jigsaw — 50 Solid Silver States in Walnut & Glass Table
  • 100 troy ounces .999 fine silver total
  • 50 individual states — each a removable jigsaw piece
  • 3D topographical detail — mountains, valleys, plains cast in relief
  • Each state individually hallmarked with name & silver purity
  • Handcrafted solid walnut display table (36″ × 24″)
  • Tempered glass top — view & protect without opening
  • Premium felt backing — choose: midnight black, royal navy, forest green, or burgundy
  • Recessed puzzle bed precision-routed to state outlines
  • Anti-tarnish treated — museum-grade preservation
Base Commission
$34,500 USD
Metal priced at day-of-order spot • ~$3,200 intrinsic silver value at current spot
Commission This Piece
✦ Gold Plating Options
Full 24K Gold Plate — All 50 states dipped in 24K gold. Solid gold continent on silver sea.
+ $4,200
Selective Gold Plate — Choose your states. Home state, states you’ve lived in, bucket list. Your story in gold.
+ $120 per state
Rose Gold Accent — Rose gold plate on select states for contrast against silver & yellow gold.
+ $150 per state
✦ Birthstone & Gem Markers
Hometown Birthstone — A genuine gemstone set into your home state at your city’s location. Your birthstone, your birthplace.
+ $85–$350 per stone
Favorite State Markers — Set stones in every state that matters. Where you proposed, where you graduated, where your kids were born.
+ $85–$350 per stone
Diamond Capital Markers — Genuine diamond chips at all 50 state capitals.
+ $2,800 (50 stones)
✦ Felt Background Colors
Midnight Black
Royal Navy
Forest Green
Burgundy
Custom colors available on request. Felt is replaceable for future refreshes.
Weight Distribution — Select States
Texas
7.2 ozt
Largest piece
Alaska
6.8 ozt
Separate display piece
California
4.1 ozt
Sierra topo detail
Montana
3.4 ozt
Rocky Mtn relief
N. Carolina
2.1 ozt
Home state ♚
Rhode Island
0.18 ozt
Smallest piece
Total: 100.0 troy ounces .999 fine silver • Alaska & Hawaii displayed as companion pieces alongside continental map
Collections
Cast in Precious Metal
Original designs vacuum cast and hand-finished in our Charlotte studio.
ðŸĶ…
Nature
Eagle in Flight — Sterling
3.5" wingspan, hand-polished. Walnut display base. Solid cast .925.
$385 / Sterling Silver
🐚
Nature
Howling Wolf — Bronze
2.8" tall, antique patina. Incredible fur strand texture.
$95 / Bronze
🐉
Nature • Fantasy
Coiled Dragon — Sterling
2.2" serpentine dragon. Crystal base. Limited edition of 50.
$520 / Sterling Silver
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D&D • Tabletop
Hero Party Set — Pewter (6pc)
28mm minis. Fighter, Mage, Rogue, Cleric, Ranger, Bard. Unpainted.
$65 / Pewter Set of 6
ðŸŽē
D&D • Gaming
RPG Dice Set — Sterling (7pc)
Full polyhedral set. D4 through D20. Gold ink number fill.
$750 / Sterling Silver 7pc
🧙
D&D • Collector
Ancient Red Dragon — Bronze
75mm centerpiece. Wing spread, flame breath. Solid bronze, 180g.
$145 / Bronze
ðŸŽŪ
Gaming • Custom
PS5 Controller Shell — Sterling
DualSense faceplate. Mirror or brushed. Custom engraving available.
$1,200 / Sterling Shell
💀
Gothic • Figurine
Memento Mori Skull — Sterling
1.5" skull desk display or pendant. 45g solid sterling. Jaw detail.
$340 / Sterling Silver
ðŸ—Ąïļ
Figurine • Mythology
Samurai Warrior — Bronze
4" standing with katana. Full armor, layered patina accents.
$175 / Bronze
♛
Chess • Fantasy
Dragon vs Knight Chess — Pewter
32-piece fantasy set. Dragon army vs. Knight army. Highly detailed.
$395 / Pewter Full Set
🊙
Silver Stacker • Bullion
Hand-Poured Art Bar — .999 Silver
5oz poured bar. Custom ForgeBorn hallmark. Each unique.
Spot + $12/oz / Fine Silver
ðŸŧ
Nature • Collectible
Grizzly Bear — Sterling
2" standing bear. Textured fur. Display base. Solid .925.
$295 / Sterling Silver
How It Works
File to Finished Metal
Your design in real metal, as fast as 5 business days.
01
Upload
Send your .STL, .OBJ, .GOO, or .3DM. Or describe your idea.
02
Quote
We calculate metal weight and quote within 24 hours.
03
Print
High-res castable resin print, inspected and prepped for burnout.
04
Cast
Burnout kiln, vacuum or sand cast in your metal, devested and cleaned.
05
Finish
Sprue cut, polished to spec. Patina, plating, or raw.
06
Ship
Insured delivery or Charlotte local pickup.
Get a Quote
Start Your Project
Upload your file or describe your idea. Quoted within 24 hours.