How it Works
Exploring the
Bronze
PRocess
Bronze casting dates back to the ancient Chinese and the process has largely remained unchanged for thousands of years. The sculptures are cast using the traditional lost-wax method.
01
SKELETON
A steel armature is fabricated that will function as a ”skeleton” to hold the weight of the clay
02
Clay
The piece is sculpted using an oil based clay
03
Rework
The piece is worked and reworked until both the artist and client are pleased
04
SCULPTURE
The finished life-size sculpture and small model
05
SECTIONS
Thin sheets of metal are used to divide the sculpture in to a predetermined number of sections
06
RUBBER
A latex rubber is applied to the clay sculpture. 5-6 coats are used to build up a sufficient thickness
07
Plaster
The molds are backed with plaster, which will give rigidity and support to the rubber
08
section mold
The plaster pieces are removed and the latex is cut down the center to create a two section mold
09
finished molds
The finished set of molds are collected
10
wax coating
The molds are coated with wax to create a copy of the clay original
11
replica
Wax is poured in, the mold is rotated to evenly coat, and the excess wax is poured out. This will create a hollow replica
12
remove wax
A finished wax being removed from the mold
13
Finished wax
One wax piece is finished
14
Runners & Cup
The pieces are touched up. Wax runners and cups are attached, which will later act as funneling system to for the bronze
15
Ceramic Coating
Pieces are coated in a liquid ceramic and dried. This will be repeated 7-8 times to build a thick ceramic shell. The shell becomes another mold
16
First coat
Finishing the first coat of liquid ceramic
17
sand coat
Next the piece is coated in sand. This will help dry it quicker and add mass to the ceramic
18
hollow shell
The ceramic is chipped away from the bottom of the cup. The piece is heated and the wax melts, leaving a hollow ceramic shell.
19
Finished wax
One wax piece is finished
20
Runners & Cup
The pieces are touched up. Wax runners and cups are attached, which will later act as funneling system to for the bronze
21
Ceramic Coating
Pieces are coated in a liquid ceramic and dried. This will be repeated 7-8 times to build a thick ceramic shell. The shell becomes another mold
22
OVEN
The ceramic shell are also heated, to prevent them from shattering from the shock of the molten bronze
23
COOLING
The shells are removed from the oven and placed in a sand filled box with the cup facing up
24
BRONZE POUR
The cup acts as a funnel and the runners carry the bronze to the piece
25
shell cleaned
Once cooled, the ceramic shell is chipped away. Then the cup and runners will be cut off.
26
finished pieces
A finished set of bronze pieces ready to be reassembled.
27
welding
Using heli-arch welders the bronze pieces are welded back together. The sculpture is ground and polished to create a seamless finish.
28
chemicals
The sculpture is heated and treated with chemicals that oxidize the bronze changing its color to the desired effect
29
final piece
The finished piece is not only beautiful but strong and durable able to last generations!
FIN
purchase
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