Honger, the old, plastic badge is what I used as a pattern. The way it works is you put your pattern down on a board, place a box called a flask around the pattern, and then pack sand over your pattern inside of the flask. This creates the bottom of the mold, known as the drag. You then flip the drag over and do it again with another flask on top, which creates the cope (top of the mold), and the cope includes a hole to pour aluminum into the sand. The part you're curious about is where you separate the cope from the drag (remember that they're two, separate boxes), and you strip the pattern out of the sand, leaving an impression of the pattern in the sand. The cope is then reassembled on the drag, so there is a void in between the cope/drag where the molten aluminum goes. I need to post some more pics--once you see it, it'll make total sense.