Lost -Wax Casting

Ancient Sculpture Gallery is proud to present you with lost wax bronze reproductions of statues and busts from the Egyptian, Greek, Hellenistic, Roman, Asian Oriental, and Western civilizations. “Lost Wax” bronze (or hotcast bronze) is actually 100% pure Bronze – essentially copper and tin. The making of a “lost wax” bronze is a complex and time consuming process, and specific technical expertise is needed to accomplish the task of making a bronze. The most known and used process for making “lost wax” involves pouring of molten bronze. This is the same method used by the ancient civilizations to create bronze sculptures. Our lost wax bronze sculptures are produced in this same technique.

Step 1 Clay Model Making

our artists team make a clay model at first, which is 100% based on customers’ request.

Step 2 Silicon Rubber Mold

This step is by far the most critical. All the detail which appears on the bronze sculpture must be captured in the mold. The mold (depending on the size of the sculpture) is cut into sections for casting.

Step 3 Wax Making and Chasing

Molten wax is poured into the mold to form layers of wax. This wax model is an exact duplicate of the original casting. Then the wax is pulled from the mold and hand chased (re-detailed) by a skilled artisan. Although the artist reproduces the original artwork, each piece may slightly differ from the next.

Wax rods (gates) and pouring cup are attached to the wax casting in just the right positions. This will assure a full pour.

Step 4 Ceramic Shell Making

In a temperature controlled climate of 72 degrees Fahrenheit, the wax casting is dipped into Investment liquid several times. On the first dip a fine powder is applied. On the next dip of course, ceramic sand will be applied. This step is repeated several times, each increasing the coarseness of the material to create the ceramic mold. Between each dip, the ceramic layer must cure (dry) before another layer can be applied.

Step 5 Burn-Out and Casting

The ceramic shell is placed in a kiln and fired. The shell bakes and the wax is melted (lost) from the shell. This creates a hollow ceramic shell mold. Thus the term “Lost Wax.” Immediately the molten bronze is poured into the shell. At the time of pouring, the bronze is 2100 degrees Fahrenheit.

Step 6 Shell Removing

After the casting has cooled several hours, the shell is carefully broken away leaving the unfinished bronze.

Step 7 Welding & Chasing

with their finest welding&chasing skills, our professional craftsmen assemble the pieces together and show all details of original for us.

Step 8 Patina

According to customers’ requests, we make unique and art-quality patina which can stand for tens of years.