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FOUNDRY
From
Start to Finish:
ARTIST'S
CLAY ORIGINAL: Once the artist has created the
original sculpture, usually in wax or clay, the process of turning this
original into a limited edition bronze begins.
MAKING
A MOLD:
The first mold, referred to as the "mother mold," is made directly from
the original clay sculpture, using coats of liquid rubber or silicon backed
with plaster or fiberglass.
POURING
A WAX PATTERN:
Hot wax is poured into the latex rubber "mother mold" and allowed to cool
for a short time. The wax is then poured out of the mold, producing a hollow
wax copy of the original sculpture.
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CHASING
THE WAX:
The wax pattern is carefully removed from the mold, inspected, and
any flaws are painstakingly removed or "chased" by hand. A wax pouring
cup and "sprues" are attached which will channel the molten bronze
into the sculpture.
ATTACHING
THE SPRUES:
A pouring cup and wax shafts (known as "sprues") are attached to each part
of the sculpture. These will ultimately serve as channels for the molten
bronze to flow through after the wax has been melted out of the ceramic
shell mold.
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| CERAMIC
SHELL MOLD:
The second mold, a rigid ceramic shell, is formed by dipping the wax
duplicate repeatedly in a vat containing liquid slurry and coating
it with silica sand. This process takes several days. The shells are
then fired in an oven to melt out the wax, and also to harden the
ceramic shell mold for receiving the molten bronze. |
| MELTING
OUT THE WAX IN A KILN:
Once the ceramic shell has dried, it is fired in a kiln in order to
harden it, and also to cause the wax to melt out from within it, leaving
the mold hollow to receive the molten bronze that will be poured into
it in the next step of the casting process.
POURING
THE BRONZE:
Molten bronze is poured into the cup of the ceramic shell mold,
into the space left behind by the "lost wax." The bronze will be
allowed to cool, and then the ceramic shell will be broken off to
reveal the bronze sculpture within.
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METAL
FINISHING:
In the next step, the individual pieces of the sculpture are welded
together. The imperfections and weld lines are "chased" out, and
the texture is restored for final finish.
PATINATION:
The last step is the coloration of the bronze sculpture through the application
of heat and different chemicals. This produces a permanent colored finish
called "patina," and completes the transformation of the sculpture into
a piece of lasting fine art.
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PLANET BRONZE ART GALLERY | 905 NORTH 5TH AVENUE | BOZEMAN, MONTANA 59715 | PHONE: (406) 585-0050 FAX (406) 585-0051
Copyright © 2004 Planet Bronze Art Gallery, All Rights Reserved
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