Step 1 Making the Mold from an Original Work of Art:

This step is by far the most critical. All the detail which appear on the sculpture must be captured in this Mold. A two part silicone mold is then created and prepared for the wax.

 

Step 2 Making the Wax Casting:

Melted wax is poured into the mold to form a wax duplicate of the original art work.  The wax is allowed to cool for several hours before being removed.

 

Step 3 Removing the Wax Casting:

The wax is pulled from the mold and compared to the original piece of art.

 

Step 4 Spruing:

Wax rods (gates) and pouring cups are attached to the wax casting to provide ventilation and ensure a full pour.

 

Step 5 Casting the Ceramic Mold:

Depending on the artwork, the wax casting is next placed in a plaster block or dipped into investment liquid and covered with ceramic until the casting has a hard shell.

Step 6 Burn-Out: 

The ceramic shell or plaster block is then fired as the pre-existing wax casting melts and burns out leaving an empty cavity. This is why the process is known as the Lost Wax Method.

Step 7 Casting:

The plaster mold is removed from the kiln and immediately the melted bronze is poured into the shell. At this time of pouring, the bronze is 2100 degrees Fahrenheit.

Step 8 Break-Out:

After the casting has cooled several hours, the shell is carefully broken away leaving unfinished bronze. At this time, all wax rods and gats are cut away and discarded.

Step 9 Sandblasting:

Any fragments of the ceramic shell are removed by sandblasting. The sculpture is also carefully inspected at this time.

 

Step 10 Assembling:

Any assembling required to complete the project is done at this time and all welds are chased.

 

Step 11 Polish:

The raw bronze now goes through a series of polishes to get the finish down to a smooth, glowing bronze.

 

Step 12 Patina:

All bronze starts with a liver of sulphur treatment to give the bronze the dark brown detail. Additional patinas are then added to produce an array of finishes.

 

Step 13 Inspection:

If the piece of art has any moving parts, lubricating oil is applied as pert of the final inspection stage.

 

Step 14 Shipping:

The art work is now ready to be packaged and shipped.