
The following steps comprise the “Lost Wax Casting” method.
A single sculpture will normally take approximately two weeks
to complete using this method. This is just quick summary of
this labor intensive process but should give you an idea how
the sculptures are made.
Step 1 Creating the mold
The initial step in creating a mold from the original
work of art is by far the most critical. All the details which
appear on the original sculpture must be captured in this mold.
The mold are made from hard rubber or plaster. The mold
(depending on the size of the sculpture) is cut into sections
for casting.
Step 2 Making the Wax Cast
Molten wax is poured into the mold to form layers of wax.
This wax model is an exact duplicate of the original casting.
Step 3 Chasing the Wax
The wax model is pulled from the mold and hand chased
(re-detailed) by a skilled artisan. Although the artisan
reproduces the original artwork, each piece may differ slightly
from the next.
Step 4 Spruing
Wax rods (gates) and pouring cup are attached to the wax
casting in just the right positions. This gate will assure a
full pour.
Step 5 Investment Casting
In this step a ceramic mold is casted. The wax casting
is dipped into the investment liquid several times in a
temperature controlled environment (at about 72 Fahrenheit)
to create the ceramic mold. The investment liquid is basically
liquid clay. The next step involves dipping the ceramic mold
into coarse ceramic sand. The ceramic sand is applied several
times, each time the coarseness of the sand is increased. Between
each application, the ceramic layer must be dry before another
layer can be applied.
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