Mold Making

 

A mold of the original sculpture is created using several thin layers of high quality silicon rubber and a fiberglass or plaster case.

 

Wax Work

Hot liquid casting wax is poured inside the rubber mold. Once cooled off, the mold is taken apart to reveal a wax replica of the original sculpture. At this point in time  finishing touches are made to the wax by a foundry technician using modeling tools and any flaws in the wax from the process can be removed.

A network of wax rods or sprues and a wax cups or attached to the wax positive. This complex procedure will provide the feeding system through which the molten metal will travel later in the process to achieve the casting.

Ceramic shell

 

A slurry mixture and varying grits of sand is applied in successive coats. Reinforcement of critical stress points is necessary. It’s a slow process because each coat has to dry before another one is applied.

 

Casting

 

The complete wax structure which is invested in ceramic, is then heated in a kiln until the wax runs out and all free moisture is removed. The ceramic shell is then filled with molten bronze.

 

 

Cleaning

 

After pouring, the ceramic shell is removed  revealing the cast bronze.  At this stage all that was once wax,  is now bronze, and so the feeder or sprue system is also removed , leaving just the casting which will now be ready for metal finishing.

Metal Chasing

 

The final finishing of the sculpture is accomplished with the help of pneumatic and electrical rotary tools. An expert welder uses welding rods to weld any seams, imperfections, or additions on the finished sculpture.

Patina

After final polishing, corrosive materials are  applied to form a patina, a process that allows  control over the color and finish. Our talented patina artists can offer a wide variety of choices and unique colors to satisfy your needs as an artist.