LOST WAX CASTING
The process begins with the artist's original piece sculpted in clay.
MAKING THE MOLD
All details of the sculpture are captured in the mold.
Molten wax is poured into the mold. It is an exact duplicate of the original.
CHASING THE WAX
Wax is pulled from the mold and hand chased (re-detailed) to match the original.
Wax rods and a pouring cup are attached to allow for gases to escape and to assure a full pour.
The wax casting is dipped into investment liquid 10 times in a temperature-
controlled climate. Fine powder is applied on the first dip and ceramic sand is applied on the others. This process creates the ceramic mold.
The ceramic shell is placed in a kiln and fired at 2,000 degrees Fahrenheit. The wax melts and this creates a hollow ceramic mold.
The ceramic shell is removed from the kiln and the molten bronze is poured into the shell at 2,100 degrees Fahrenheit.
ROVING THE CERAMIC SHELL
The casting is cooled for several hours before the shell is broken away.
SANDBLASTING & ASSEMBLY
Sandblasting removes any fragments of the ceramic shell.
In the case of a monumental sculpture or any sculpture cast in more than one piece, the sections are assembled at this time.
Pieces of the sculpture are welded together.
CHASING & 7 GLASS BEADING
Weld marks are chased, re-detailed and sanded. Sculpture is blasted with fine glass beads.
FINAL PROCESS PATINA
The piece is heated and a patina chemical is applied by hand for colorization.
Wax is applied by hand with heat to protect the piece.