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BRONZE FOUNDRY



Small bronze castings from clay to final product



molding



I use the lost wax method for bronze casting, which has been used since ancient times. The first bronze molded figure is dated over 4500 years ago and the Greeks used this process on a large scale 2500 years ago. I use an oil based clay to creat the original sculpture. To mold this clay, liquid silicon is brushed on each half of the clay and allowed to harden to create 2 halves. A harder material such as plaster is then poured over the soft mold to create a rigid outer mold as shown in the figure to the left. Registration dimples are created in the 2 halves so they can go back togeher correctly. If there are nonsymetric parts then these are cut off and molded separately. The clay original is removed from the mold, and the mold cleaned. The original clay can be damaged during this process so the mold has to be consturcted correctly and carefully.



Wax positive



Molten wax is poured into the mold and rotated until an even coating of about 1/8 inch covers the inner surface of the mold. After the wax is cool, the mold is opened and the wax postivie is removed. This mold may be reused to make multiple copies. Each wax positive is then worked to remove parting lines and defects. Wax pieces that were molded separately can be heated and attached. Small cylinders of wax called spues are attached to the wax postive to provide paths for molten bronze to enter the mold and to allow air to escape. A wax cup is attached to these spues which is where the molten bronze will be poured. See the figure to the left where the cup is shown at the bottom.



Ceramic shell & Burn Out



A sprued wax copy is dipped into a slurry of silica, then into a stucco like mixture. This shell is then allowed to dry, and the process is repeated several times. The shell is then placed cup-down and torched at high tempertures or placed in a kiln for several hours for large pieces. The heat hardens the silical, and the wax melts and runs out. This is now a hollow negative.



bronze cast



The shell is then reheated to remove all moisture, then placed cup side up into a sand pit. Bronze metal is melted in a graphite crucible in a gas furnace, then lifted out with tongs. The crucible is then lifted with a pouring shank and the liquid bronze is poured into the shell . The filled shells are allowed to cool. The shell is then hammered and sand-blasted away to reveal the bronze casting. The sprues are also cut off.


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chase and patina



The casting is then worked with tools to remove parting lines. All defects such as air bubbles or pits are filed down and then polished or sand blasted. Patina is applied by hand or spray and usually requires several coats and can be applied with a torch as shown in the picture. After cooling the finished piece is then given a wax coating to preserve the finish. A marble or wood base is added to figurines.





505-206-0654
11800 Signal Ave NE, Albuquerque Nm 87122



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