THE PROCESS

Whether  made in the "lost wax" or "cold cast" method, each bronze piece begins with a mold made from the artist's original sculpture.

LOST WAX METHOD

Melted wax is poured into the mold to create a hollow shell, the cooled wax is removed and the artist repairs any damage and further refines the piece. This process can take days or even weeks depending on the sculpture. When the wax  work is finished it goes to the foundry where it is coated in several layers of liquid silica. When the silica hardens it is placed in a VERY hot oven and the wax is melted out (hence the term "lost wax"). Next, molten bronze , sometimes as hot as 2,200 degres, is poured into the silica shell. The bronze is allowed to cool and the shell is then chipped and sandblasted away. Now the metal work begins. Sculptures that have been cut apart and cast in more than one piece must be welded back together. The seams and imperfections are painstakingly removed with metalworking tools. The sculpture is now ready to receive its patina. The bronze is heated to red hot and different chemicals are applied to achieve the desired results. Each chemical produces a different color when it comes in contact with the hot metal and the color combinations are nearly limitless. Finally, a coat of hot wax is applied, allowed to cool completely and polished to bring out the luster of the bronze.

COLD CAST BRONZE

In the "cold cast" method, the mold is dusted with finely ground, real bronze powder. It is then filled with a resin that has been impregnated with a high concentration of bronze powder and bronze flake. Once hardened, the sculpture is removed from the mold and the artist corrects any imperfections. Finally, it is buffed to bring out the bronze luster and sealed with either melted paste wax for inside use or a weatherproof acrylic for use outside. If paste wax is used the sculpture must be polished again when the wax hardens.

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