Lost Wax Casting Process:
Step 1, Making the Mold. This is by far the most critical. All the detail which appears on the sculpture must be captured in the mold. The mold (depending on the size of the sculpture) is cut into sections for casting.
Step 2, Making the Wax Casting. Molten wax is poured into the mold to form layers of wax.
Step 3, Chasing the Wax. The wax is pulled from the mold and hand chased (re-detailed) by a skilled artisan. Although the artist reproduces the original artwork, each piece may be slightly different.
Step 4, Spruing. Wax rods (gates) and pouring cups are attach3ed to the wax casting in just the right position. This will assure a full pour.
Step 5, Casting the Ceramic Mold. Ina temperature controlled climate of 72 degrees Fahrenheit, the Wax casting is dipped into investment liquid several times. On the first dip a fine powder is applied. On the next dip of course, ceramic sand is applied. This step is repeated several times, each increasing the coarseness of the material to create the ceramic mold. Between each dip, the ceramic layer must cure before another layer can be applied.
Step 6, Burn-Out. The ceramic shell is placed in a kiln and fired. The shell breaks and the was is melted from the shell. This creates a hollow ceramic shell mold. Thus the term “Lost Wax”.
Step 7, Casting. The ceramic shell is removed from the kiln nd immediately the molten bronze is poured into the shell. At the time of pouring, the bronze is 2100 degrees Fahrenheit.
Step 8, Break-Out. After the casting has cooled several hours, the shell is carefully broken away leaving the unfinished bronze.
Step 9, Sandblasting. Any fragments of the ceramic shell are removed by sandblasting. The sculpture is also carefully inspected at this point.
Step 10, Assembly. At this time all the pieces of the sculpture are welded together by our skilled craftsmen.
Step 11, Chasing. All the weld marks are chased and re-detailed.
Step 12, Glass Beading. This is similar to sandblasting. The glass is extremely fine to ensure an even bronze finish.
Step 13, Polish. The raw bronze sculpture is now hand polished in preparation for the patina.
Step 14, Patina. The bronze is first heated. The patina chemical is hand applied by our skilled artist.
Step 15, Waxing. The wax is hand applied with heat to ensure a beautiful lustrous patina.
Step 16, Mounting and Inspection. The bronze is mounted on a marble base and the final inspection will take place, allowing you to receive a fine quality sculpture.
Step 17, Shipping. The sculpture is now ready to be packaged and shipped.