Lost Wax Bronze Casting Process
following is the step by step process of the “Lost Wax Casting”
method. After reviewing this process, which normally takes approximately
two weeks to complete a single sculpture, you will have a better
understanding of all that is involved.
1 Making the Mold: This step 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.
2 Making the Wax Casting: Molten
wax is poured into the mold to form layers of wax.
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 slightly differ 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 full pour.
5 Casting the Ceramic Mold (Investment Casting): In
a 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 will be 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 (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 mold. Thus the term “Lost Wax.”
7 Casting: The
ceramic shell (mold) is removed from the kiln and immediately
the molten bronze is poured into the shell. At the time of pouring,
the bronze is 2100 degrees Fahrenheit.
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 welded together
by our skilled craftsman.
11 Chasing: All
the weld marks are chased and re-detailed.
12 Glass Beading: This
is similar to sandblasting. The glass is extremely fine to ensure
an even bronze finish.
13 Polish: The
raw bronze sculpture is now hand polished in preparation for the
bronze is first heated. The patina chemical is hand applied by
our skilled artist.
15 Waxing: The
wax is hand applied with heat to ensure a beautiful lustrous patina.
16 Mounting and Inspection: The
bronze is mounted on a marble base and the final inspection will
take place. Our customer will be assured to receive a fine quality
17 Shipping: The
sculpture is now ready to be packaged and shipped.
A Division of Prime Equine Co. of South Texas
Post Office Box
Boerne, Texas 78006
Toll Free:1 800-592-7778
Catalog Biography Casting
M.D. Anderson Cancer Center, University
of Texas, Autistic
Treatment Centers of Texas
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