Pictured above is one of the preferred methods of pattern shell manufacturing.  The key to success in producing a good pattern shell is to 1.) Precisely create the desired shape using a two dimensional star pattern inside the shell.  2.) Use a method to maintain integrity of star placement even after rough handling of the shell.  3.) Utilize a well constructed shell with uniform case strength.

Note the thin cardboard cut-outs in the upper center of the picture.  Also, note the white tubes, which are made of tissue paper and filled with small stars.   The tissue paper tubes are then glued to the cut-out and the whole assembly is placed in the shell on top of a burst of black powder coated rice hulls. This method allows the precise star pattern to be reproduced with each shell and it prevents the stars from moving during rough handling.

Pictured is a typical star rolling machine used in China's factories.  This machine is made of non-sparking brass for safety reasons.  

Also for safety, the electric motor that drives the drum is located on the other side of the concrete wall.  A solid shaft penetrates the wall and drives the drum.

Workers use a gloved hand to reach into the drum and keep the stars evenly tumbling thus avoiding any clumping and keeping all the stars growing at a uniform rate.

Many of the modern star formulas use a non-aqueous binder to speed up drying time, this is particularly important in the high volume environment of a modern Chinese factory.  

The technicians of the best factories have become experts at star rolling and can make extremely uniform stars with amazing productivity.

We have many more photo's for the gallery.  Stop back soon and look for updates.