The following is the step by step process of the "Lost Wax Casting" method. After reviewing this process, which normally takes approximately three weeks to complete a single small-sized sculpture, you will have a better understanding of all that is involved in casting.
Step 1 Making the mold from the original work of art: This step is by far the most critical. All the detail of the original sculpture must be captured in this mold.
Step 2 Making the wax casting: Molten wax is poured into the mold to form layers of wax. This wax model is an exact duplicate of the original sculpted model.
Step 3 Chasing the wax: The wax is pulled from the mold and hand chased (re-detailed) by a skilled artisan.
Step 4 Spruing: Wax rods (gates) and a pouring cup are attached to the wax casting in just the right positions to assure a full metal pour.
Step 5 Casting the ceramic mold (ceramic shell): In a temperature controlled climate, the wax casting is dipped into liquid ceramic shell material. 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 dip increases the coarseness of the material to create the ceramic mold. Between each dip the ceramic layer must cure (dry) before another layer can be applied.
Step 6 Burn-out: The ceramic mold is fired in a kiln. The shell bakes and the wax is melted (lost) from the shell. This creates a hollow shell mold. Thus the term "Lost Wax".
Step 7 Casting: The ceramic shell mold is removed from the kiln and immediately molten bronze is poured into the shell. At the time of pouring the bronze is 2100 Fahrenheit.
Step 8 Break-out: After the casting has cooled, the shell is carefully broken away leaving the unfinished bronze.
Step 9 Sandblasting: removes any fragments from the ceramic shell.
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 Sandblasting: After all the metal finishing has been performed the sculpture is sandblasted for a final time to ensure an even bronze finish for the patina.
Step 13 Patina and Waxing: The bronze is first heated with a torch and then the patina chemicals are hand applied by a skilled artist. Several applications are applied in order to achieve the proper color qualities desired. The piece is then waxed with heat and polished to ensure a beautiful luster.
Step 14 Mounting: The sculpture is mounted on wood or marble depending on the customer's preference and the final inspection will occur.
Step 1 Making the mold from the original work of art: This step is by far the most critical. All the detail of the original sculpture must be captured in this mold.
Step 2 Making the wax casting: Molten wax is poured into the mold to form layers of wax. This wax model is an exact duplicate of the original sculpted model.
Step 3 Chasing the wax: The wax is pulled from the mold and hand chased (re-detailed) by a skilled artisan.
Step 4 Spruing: Wax rods (gates) and a pouring cup are attached to the wax casting in just the right positions to assure a full metal pour.
Step 5 Casting the ceramic mold (ceramic shell): In a temperature controlled climate, the wax casting is dipped into liquid ceramic shell material. 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 dip increases the coarseness of the material to create the ceramic mold. Between each dip the ceramic layer must cure (dry) before another layer can be applied.
Step 6 Burn-out: The ceramic mold is fired in a kiln. The shell bakes and the wax is melted (lost) from the shell. This creates a hollow shell mold. Thus the term "Lost Wax".
Step 7 Casting: The ceramic shell mold is removed from the kiln and immediately molten bronze is poured into the shell. At the time of pouring the bronze is 2100 Fahrenheit.
Step 8 Break-out: After the casting has cooled, the shell is carefully broken away leaving the unfinished bronze.
Step 9 Sandblasting: removes any fragments from the ceramic shell.
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 Sandblasting: After all the metal finishing has been performed the sculpture is sandblasted for a final time to ensure an even bronze finish for the patina.
Step 13 Patina and Waxing: The bronze is first heated with a torch and then the patina chemicals are hand applied by a skilled artist. Several applications are applied in order to achieve the proper color qualities desired. The piece is then waxed with heat and polished to ensure a beautiful luster.
Step 14 Mounting: The sculpture is mounted on wood or marble depending on the customer's preference and the final inspection will occur.
Wow. I was going to ask you how you made your scuptures but decided to try and find out on my own and here it all is. Thank you, Emory. I am impressed. We have a foudry near by that does some of Debbie Butterfield's horses, etc. It is just outside of Walla Walla. I visited there a couple of time. Told I should be a scuptor because of my interest in form, but I never followed through. Your work is beautiful.
ReplyDeleteThank you for showing it to me and telling me how it is made. ~giudetta