| Creating the Mold from the original work of art is by far the most critical step. All the details, which appear on the original sculpture, must be captured in this mold. Making the Wax Cast is accomplished by pouring molten wax into the mold forming layers of wax. This is repeated until the correct measurement is attained, approximately 1/8 inch. |
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Chasing the Wax is done once the wax model is pulled from the mold. The piece is then hand chased by a skilled artisan to reproduce the original artwork.
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Spruing is the name given to the wax rods (gates) and pouring cups attached to the wax casting in just the right positions. This assures a full pour into each portion of the piece.
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| Investment Casting is the step in which the ceramic mold is cast. The wax casting is dipped into the investment liquid several times in a temperature-controlled environment to create the ceramic mold. The investment liquid is basically liquid clay. Once this is done, the ceramic mold is dipped into coarse silicon sand. The ceramic sand (slurry) is applied several times, each time the coarseness of the sand is increased. Each layered application must be dry before another layer can be applied. |
| Burn-Out is where the process gets it name, because this is where the wax is lost. The shell is placed into a kiln and fired at 1800 degrees in order to melt the wax and drain it completely from the shell, leaving only the hollow ceramic mold. |
| Casting is the art of pouring molten bronze into the shell immediately after it is removed from the kiln. The molten bronze must be at a temperature of 2500 degrees Fahrenheit at the time of pouring. |
| Break-Out occurs after the bronze has a chance to cool down. The shell is carefully chipped away revealing the unfinished bronze. |
| Sandblasting is the next process. This removes any fragments or residue remaining after the Break-out. The sculpture is fully inspected at this point. |
| Assembly. In most cases, the original sculpture has to be divided into manageable pieces before the process begins. Once the sandblasting is approved, these pieces are welded together. |
Chasing is an extremely important part of the Lost Wax Process, because all weld and seam lines are erased at this time.
Polish. The sculpture is polished by hand in preparation for the patina.
Patina is not paint. To achieve this effect, the sculpture is first washed in an acid bath, and then heated under high temperature. The patina (color) is then applied by hand and heated into the sculpture creating a long lasting finish.
Waxing is the final process and is accomplished by applying heated past wax to the sculpture by hand. This again ensures a beautiful patina by further enriching the various colors. |
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