The Process of Bronze Sculpture Casting

Preliminary Step: Making a small clay sculpture (each product needs an original clay sculpture prototype. The clay sculpture is a re-creation by the sculptor based on the original design draft after repeated contemplation and refinement. The quality of the clay sculpture's shape, expression of spirit, and manifestation of the intended meaning directly affects the quality of the final product. Therefore, an excellent clay sculpture cannot be separated from an excellent sculptor.)

Second Step: Applying a thick layer of clay to cover the sculpture form. While applying the clay, use a wooden mallet to compact it and fill in any gaps. After fully covering with clay, continuously adjust the overall form. The form may need to be reworked and the armature readjusted until satisfactory. This must be done by a professional sculptor. From this stage onwards, the sculpture must be frequently sprayed with water to prevent cracking. During breaks, it must be covered with plastic film to retain moisture until the sculpting is complete.

Third Step: Making the clay sculpture original (The silicone mold made is now complete and in good condition. Molten wax is injected under pressure into the silicone mold to create a wax prototype, which is an accurate replica of the final product's external form.)

Fourth Step: Once the large-scale sculpture is complete, notify the client to review the overall form and provide feedback or suggestions for modification. Continue to refine and sculpt the details until perfection is achieved. After the entire form is complete, smooth and polish the clay sculpture using a scraper. The clay sculpture original needs to be adjusted again by referring to the prototype from the third step. This is a very important step, as it will directly affect the final product's form and surface effect.

Fifth Step: Enter the mold-making stage. Slice the clay sculpture into sections for mold design, then spray with soapy water as a separating agent. Professional mold-makers mix plaster slurry in specific water ratios for the inner and outer layers and apply it over the sculpture. Once the plaster hardens and dries, begin demolding by attaching handles made of plaster and burlap to the sections.

Sixth Step: After demolding, remove any remaining clay from the plaster molds, then carefully repair and smooth the molds. Finally, reinforce with metal copper mesh.

Seventh Step: Casting (The hollow ceramic shell from the previous step is placed in a kiln and fired at 1000°C-1150°C depending on the alloy material. Molten copper is immediately poured into the shell. After cooling, the outer ceramic shell is broken off, revealing the rough copper casting.)

Eighth Step: Product casting refinement and processing (The cast copper product undergoes sandblasting and cleaning, as well as grinding, heat treatment, forming, machining, and polishing.)

Ninth Step: Surface effect processing and protection (Achieve the desired surface effect on the cast bronze, typically either cold patination or hot patination. We will introduce the distinctions and characteristics of these patination methods in future articles.) Finally, apply wax coating and polish.

Tenth Step: Oiling and waxing Oiling and waxing allows our cast bronze sculptures to maintain their appearance for a long time.

Eleventh Step: Artistic supervision Artistic supervision determines whether our cast bronze sculptures will be accepted by the audience. It generally requires professional training or artistic talent.