Bronze Casting Process

1. Making the Mould From An Original Work of Art: This step is by far the most critical. All the detail which appears on the original sculpture must be captured in this mould. The mould (depending on the size of the sculpture) may be made in sections if it is a complicated or large sculpture.

2. Making the Wax Casting: Molten wax is poured into the mould to form layers of wax. This wax model is exact duplicate of the original casting.

3. Chasing the Wax: The wax is pulled from the mould and hand chased (re-detailed) by a skilled artisan. Although the artist reproduces the original artwork, each piece may be slightly different from the next.

4. Spruing: Wax rods (gates) and pouring cup are attached to the wax casting in just the right positions. This will assure a complete pour with no air traps.

5. Casting the Ceramic Mould (Investment Casting): The wax casting is dipped into Investment liquid several times. On the first dip a fine powder is applied. On the next dip a course ceramic sand will be applied. This step is repeated several times, each increasing the coarseness of the material to create the ceramic mould. Between each dip, the ceramic layer must cure (dry) before another layer can be applied.

6. Burn-Out: The ceramic shell is placed in a kiln and fired. The shell bakes and the wax is melted (lost) from the shell. This creates a hollow ceramic shell mould. Thus the term "Lost Wax".

7. Casting: The ceramic shell (mould) is removed from the kiln and immediately the molten bronze is poured into the shell. At the time of pouring, the bronze is around 1350 degrees Celsius.

8. Break-Out: After the casting has cooled several hours, the shell is carefully broken away leaving the unfinished bronze.

9. Sandblasting: Any fragments of the ceramic shell are removed by sandblasting. The sculpture is also carefully inspected at this point.

10. Assembly: At this time all the pieces of the sculpture are brazed together by the skilled craftsman.

11. Chasing: All the brazing (weld) marks are chased and re-detailed.

12. Patina: The bronze is first heated. The patina chemical is hand applied by the skilled artist. The finished patina can really make a sculpture come to life!

13. Waxing:  The wax is hand applied with heat to ensure a beautiful lustrous patina.

14. Mounting and inspection: If need be,the sculpture is mounted on a suitable base before the final inspection from the artist.