Condar’s Half Kettle Steamer is crafted from recycled Cast Aluminum in a family owned foundry, right here in the USA. 

The Birth of the Condar Half Kettle
The Half Kettle began with a detailed set of blueprints, showing thickness, curves, and other dimensions.  In accordance with these blueprints, the Pattern Master carved an exact replica of the Half Kettle called the Master Pattern. 

A second pattern was sculpted to form the inside of the kettle.  This inner pattern is necessary because the Half Kettle is a “core” casting, meaning it has a large hollow area that must be formed to exacting standards.  Core patterns and castings are much more complex than regular “flat” castings.

The hand-crafted Master Patterns were then used to produce a Production Pattern, made from Aluminum, and cast as part of a large rectangular plate.  The plate allows the pattern to be mounted on a special mold-making machine.  Separate Production Patterns were made for the body of the Half Kettle, the lid, and the hollow center.

Production Patterns were then pressed into a special kind of sand, which rigidly holds its shape, forming Sand Molds.  A Sand Mold was made for both the back and the front of the kettle.  

Subsequently, each Half Kettle is created by pouring molten Aluminum into the two Sand Molds.  Before the two halves are mated, a Core Pattern is placed in the hollow of the Sand Mold.  The core is made of a special substance formulated to withstand the heat of the molten Aluminum for a short time. 

The red-hot liquid metal is then poured into the mold.  Once the molten metal starts to cool, the Core Pattern ignites and is instantly consumed by flames, leaving a cavity to form the inside of the Half Kettle.

The sand is shaken off the mated kettle, and it is sent to the machine shop for grinding, finishing, and drilling. The Burnished Aluminum Half Kettle is polished to a finish similar to pewter. The Classic Black version is finished with a special high-temperature paint.  (Please note: You may notice a slight odor when using for the first time.  This odor will disappear once the paint has cured.)

Caution
If your Half Kettle has run dry and your stove is still hot, allow the kettle to cool before adding more water.  Pouring water into a hot empty kettle can result in a flash of steam, causing serious burns.

Do not drink water out of the Half Kettle. It is for humidification only.