Lost Wax Casting Process
*First, a clay model is created...
*Then, a rubber latex mold is made over the clay model. This is overlayed with a plaster and fiberglass "mother mold" to help keep the flexible rubber mold in position.
*A hollow wax copy is poured from the rubber mold. This is done in pieces that will be put back together once it is poured in bronze. It is at this point gates, vents and a pour spout are added in wax to facilitate the flow of the molten bronze.
*The completed wax is dipped in a silicon sand slury, and coated with over eight separate layers. The "window" cut out of the form helps insure coating inside. This is important to be able to cast the piece hollow.
*The cured silicon sand molds, with the wax inside, are put in the burn-out oven. The molds are heated for casting and the wax evaporates out, or becomes "lost".
*Now, while the molds are still hot, the liquid bronze is poured into and fills each mold, including all gates, vents and pour spouts.
*All of the remaining shell material is cleaned off the cast bronze, and the gates and vents are all cut off.
*The various parts are put together, all "windows" are closed, and all seams are hand chased and finished. The finished work is sand-blasted in preparation for its patina.
*The casting is now ready for its patina, or coloring. This is done with a variety of acids which chemicaly react with the surface of the bronze to create a variety of colors and effects.
*The work is now finished, and ready for generations of enjoyment.