Bronze Reproduction

Bronze sculpture is generally created using the traditional "lost wax" casting method. A rubber mold is made of each component of the original sculpture. The molds are used to produce wax duplicates for the original piece. In the case of the P-51 Mustang sculpture this step requires making 15 molds and then 15 corresponding wax components for each sculpture produced. Cast wax pieces are assembled, “chased” (inspection and repair process) and then coated in a ceramic slurry to build up a refractory shell mold. The ceramic shell is placed in an oven and the wax is melted from within, hence the term “lost wax”. This process leaves a cavity inside the shell mold of the part to be cast. The shell mold is kiln fired and is now able to withstand the high temperature of molten bronze metal. The shell mold is supported in sand and molten bronze metal is poured into the mold. After the metal cools the ceramic mold material is broken away revealing the cast bronze part. These parts are cleaned, repaired if necessary, and readied for welding and assembly with all other bronze components. The assembled sculpture is cleaned and then skilled artisans apply the final colour patina as directed by the artist. A variety of chemical treatments with heat application produces the range of colors. The process of creating bronze sculpture is very labour intensive and involves numerous skilled artisans throughout the many steps. A source for additional information on the “lost wax” bronze casting process is available on the links page.

Pouring wax into a part mold.		Removing wax component from mold.		Wax components assembled and “chased”.
Sprue and gating attached to flow metal to extremities.		Ceramic mold completed and bronze poured.		Bronze components welded and refined.
Final cleaning and preparation for patina.		Patina application processes.		Patina completed.

Page 3 - Completion - click to view