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Bronze Casting Process Explained
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5. Spruing the Wax Model
To create channels for molten bronze, wax rods called sprues are attached to the wax model. They will create pathways for the metal to flow and for gases to escape.
1. Creating the Original Model
An artist creates an original sculpture using a malleable material like clay, wax, or another medium. This model details the exact form and texture of the final cast.
2. Making the Mold
A mold is made from the original model. Silicone rubber or plaster is commonly used to make a negative imprint that will capture the fine details of the sculpture.
4. Wax Chasing
Any imperfections in the wax copy are corrected in the wax chasing phase. Artists may use heated metal tools to refine the details and repair seams or other blemishes.
3. Pouring the Wax
Hot, liquid wax is poured into the mold's cavity. Once cooled, this creates a solid wax copy of the original model which is removed from the mold.
9. Removing the Shell
After the bronze has cooled and solidified, the ceramic shell is carefully chipped away. Any remaining parts of the shell are removed through sandblasting.
8. Pouring the Bronze
Molten bronze is poured into the hollow cavity of the ceramic shell. Once cooled, the bronze takes the shape of the original model.
6. Applying the Slurry
The wax model is dipped into a ceramic slurry, then coated with fine sand and stucco. The process is repeated until a thick shell is formed around the model.
10. Metal Chasing and Patination
The final touches are made to the bronze sculpture. Metal chasing involves smoothing out imperfections and redefining details. Patination is applied to achieve the desired coloration and surface finish.
7. Burnout and Melting the Wax
The ceramic shell-coated wax model is heated in a kiln. This hardens the shell and melts the wax out, leaving a hollow cavity.
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