The Process

Stages of the Sculptures

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

WAX CASTING

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. 

 

SPRUNG

Wax rods and a pouring cup are attached to allow for gases to escape and to assure a full pour. 

 

INVESTMENT CASTING

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.

 

BURN-OUT

The ceramic shell is placed in a kiln and fired at 2000 degrees. The wax melts and this creates a hollow ceramic mold. 

 

CASTING

The ceramic shell is removed from the kiln and the molten bronze is poured into the shell at 2100 degrees. 

 

ROVING THE CERAMIC SHELL

The casting is cooled for several hours and the shell is broken away. 

 

SANDBLASTING & ASSEMBLY

Sandblasting removed any fragments of the ceramic shell.

In the case of a monumental sculpture or any sculpture cast is 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.

 

WAXING

Wax is applied by hand with heat to protect the piece. 

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