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Casting the Bronze:

The process of manufacturing bronze sculpture has changed very little in essence since it's earliest days some more 3000 years ago in China .

In this section we explain the surprising procedures involved in manufacture, each of which requires a very high degree of hand making.

1. From original sculpture model to rubber mould: usually the original model is made in a variety of material including clay、wax and types of plasticize; from the model a mould is taken using specific grades of silicon rubber depending on the degree of strength required.

2. Remolding: Liquid wax is poured into the mould and allowed to set hard. Once this is achieved, the wax model can be drawn from the mould. Care has to be taken to ensure the wax is not broken. Where the mould joins, a seam is created which has to be removed using a knife or scalpel.

3. Ceramic Mix: Times ago the actual casting of bronze was done in sand pits but this tried and trusted method has been replaced by encasing the model in layers of liquid ceramic. When a sculpture has been covered by layers of ceramic mix and is ready for bronze casting. The wax rods seen attached to the model facilitate the flow of bronze and help the air and gas to escape. Detailed knowledge is required to know where to position the rods.

4. Removal of Wax and bronze dispensing: The wax inside the mould now has to be heated and removed to allow a cavity to be formed into which the liquid bronze can be poured. Bronze is an alloy of copper and smaller quantities of tin. It is heated to 1300c and poured into the handling vessel illustrated. At this stage the heat is intense and two operatives are required to take the vessel to the moulds.

5. Casting the mould then mould filled: The moulds are placed in a sand filled container to prevent the ceramic container injuring the operatives in the unlikely event of a shattering. The vessel then fills the moulds to the required depth. The liquid bronze can just be seen in the moulds which will be left for 24 hours to cool. Patience is required to prevent the process being hurried and the model damaged.

6. Breaking open ceramic mould and metal chasing: Once the ceramic case is cool the operator can break it. The bronze inside is extremely hard and not usually marked in this process. The bronze sculpture once removed from the case requires chasing, the removal of any seams, lines or blemishes. It takes time and skill to reinstate the model to the sculptors original. A high speed drill and selection of chasing tools can be seen on the worktable.

7. Patina and finished: The procedure finishes the bronze to the required colour and is considered to be one of the most skillful jobs in the foundry. The process of applying the appropriate acids and subsequently burnishing them takes much training since the effects can only be seen when the whole process is complete. Final waxing of the model enhances the colour and produces the reflective sheen. With care and skill many finishes and colours can be achieved.

 

 

 

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