Lost-Wax Casting Method
Each bronze sculpture undergoes a meticulous multi-step process, transforming clay into timeless metal art.
This ancient technique, refined over centuries, ensures every detail is captured with precision.
- The original piece is sculpted in clay
- The mold making process includes cutting off any pieces that can't be molded on the main piece, and then applying the first coat of rubber on the surface of the clay.
- Several more coats of rubber are added to each sculpture.
- Plaster is applied to the rubber mold to create the "mother" mold which holds the latex rubber mold in place.
- The mother mold is removed and liquid wax is coated to the inner surface of each mold.
- The two halves of the rubber and mother mold are assembled, so that hot liquid wax can be poured into the mold. This will coat the entire inner surface and the excess wax is poured off.
- The mother mold is removed from the rubber mold and the latex rubber mold is carefully peeled away.
- The wax is chased (all imperfections removed) and sprue bars (passageways for the molten metal to flow) are attached to the wax sculpture
- The sprued wax is dipped in a liquid ceramic mixture and dusted with sand to strengthen each layer. This will allow the bronze to be cast hollow.
- The wax is melted out, hence the name "lost wax" method of bronze casting.
- Bronze bars have been heated to 2020 degrees and poured into the hollow shell. After the metal cools, the ceramic shell is broken apart to reveal the cast metal.
- The sprue bars are cut off the pieces, reassembled and welded together. Metal chasing grinds away the weld marks.
- The metal is sandblasted readied for patina.
- The patina's oxidation caused by chemicals applied to the metal.
- The final step is adding the finished sculpture to the base.