Classic Foundry
The Casting Process
Classic Foundry
The Casting Process
MOLD MAKING
The first step in the bronze casting process is mold making. A mold of the original sculpture is created using several thin layers of high quality silicon rubber and a fiberglass or plaster case.
WAX WORK
Next, hot liquid casting wax is poured inside the rubber mold. Once cooled off, the mold is taken apart to reveal a wax replica of the original sculpture. At this point finishing touches are made to the wax by a foundry specialist using modeling tools. Any flaws from the process can be removed from the wax form.
A network of wax rods or sprues, as well as wax cups, are attached to the wax positive. This complex procedure will provide the feeding system through which the molten metal will travel later in the process to achieve the casting.
CERAMIC SHELL
Once wax forms are ready for the next stage, a slurry mixture and varying grits of sand are applied in successive coats. Reinforcement of critical stress points is necessary. This process is one of the most time consuming stages of casting – It’s a slow process because each coat has to dry before another one is applied.
CASTING
Now, that the complete wax structure has been invested in ceramic, it is then heated in a kiln until the wax runs out, and all free moisture is removed. The ceramic shell is then filled with molten bronze.
CLEANING
After pouring, the ceramic shell is removed revealing the cast bronze. At this stage, all that was once wax, is now bronze, and so the feeder or sprue system is also removed, leaving just the casting, which will now be ready for metal finishing.
METAL CHASING
The final finishing of the sculpture is accomplished with the help of pneumatic and electrical rotary tools. An expert welder uses welding rods to weld any seams, imperfections, or additions on the finished sculpture.
PATINA
After final polishing, corrosive materials are applied to form a patina, a process that allows control over the color and finish. Our talented patina artists can offer a wide variety of choices and unique colors to satisfy your needs, as an artist.
MOLD MAKING
The first step in the bronze casting process is mold making. A mold of the original sculpture is created using several thin layers of high quality silicon rubber and a fiberglass or plaster case.
WAX WORK
Next, hot liquid casting wax is poured inside the rubber mold. Once cooled off, the mold is taken apart to reveal a wax replica of the original sculpture. At this point finishing touches are made to the wax by a foundry specialist using modeling tools. Any flaws from the process can be removed from the wax form.
A network of wax rods or sprues, as well as wax cups, are attached to the wax positive. This complex procedure will provide the feeding system through which the molten metal will travel later in the process to achieve the casting.
CERAMIC SHELL
Once wax forms are ready for the next stage, a slurry mixture and varying grits of sand are applied in successive coats. Reinforcement of critical stress points is necessary. This process is one of the most time consuming stages of casting – It’s a slow process because each coat has to dry before another one is applied.
CASTING
Now, that the complete wax structure has been invested in ceramic, it is then heated in a kiln until the wax runs out, and all free moisture is removed. The ceramic shell is then filled with molten bronze.
CLEANING
After pouring, the ceramic shell is removed revealing the cast bronze. At this stage, all that was once wax, is now bronze, and so the feeder or sprue system is also removed, leaving just the casting, which will now be ready for metal finishing.
METAL CHASING
The final finishing of the sculpture is accomplished with the help of pneumatic and electrical rotary tools. An expert welder uses welding rods to weld any seams, imperfections, or additions on the finished sculpture.
PATINA