Art Castings of Montana, Inc
The Lost Wax Casting Process
About 3500 B.C. the earliest known lost wax casting was produced.
Ironically the process has changed little since.
The sculpture is coated with a synthetic rubber molding material then cut in half creating a front and back piece for each mold. A plaster outer shell or a (mother mold) is used to provide stability to the rubber mold. Because of the mold, a piece of art can be re-produced many times. It is the only component in the process that is ever re-used
The replica is then "chased" to remove any seam lines, pits, bubbles, or other imperfections in the wax without changing the integrity of the artists original texture.
The quality of the finished bronze depends on this step in the process.
The purpose of this is to allow for air venting, and also to enable the bronze to flow smoothly when poured.
This creates a ceramic shell that can with stand the pressure and extreme temperature associated with the casting of bronze.
The temperature is then increased to 1200 degrees Fahrenheit which cures the shell. The curing process strengthens the shell so it can withstand the molten bronze being poured into it.
The molten bronze is then poured into the cured shells and allowed to cool.
Once cooled the ceramic shell is completely broken away using an air hammer and chisel.
Pieces of a sculpture are then welded together and any imperfections are removed, and the artists original texture is re-created if necessary.
Upon completion the sculpture is then sandblasted in preparation for the patina process.
The choices are endless, ranging from traditional bronze to full color effects.
Depending on indoor or outdoor placement, there are several ways to seal the color of the patina for years of enjoyment.
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