Define the hammer type, size, and material requirements
Create a detailed 3D model or technical drawing of the hammer head
Add draft angles and shrink allowance for the chosen casting material
Split the design into mold halves along the best parting line
Design the gating, risers, vents, and core features if needed
Select the mold material, such as sand, steel, or aluminum
Prepare the pattern or master model of the hammer head
Build the mold box or mold frame
Pack or pour the mold material around the pattern
Remove the pattern carefully to form the cavity
Cut and finish the gating and vent channels
Install any cores or inserts if the design requires them
Close and align the mold halves securely
Preheat or dry the mold if required by the casting process
Pour the molten metal into the mold cavity
Allow the casting to cool and solidify
Break open or separate the mold
Remove the hammer head casting
Trim gates, risers, and excess metal
Machine or grind the striking faces and handle socket
Inspect dimensions, surface quality, and defects
Assemble the handle and finish the hammer head
Test the hammer for balance, fit, and durability