Many people ask me, while I am sculpting, if the entire clay sculpture is somehow dipped into a large vat for bronzing. Not knowing the process, this would be the natural idea. However, the process is not so easy, and this is why a bronze sculpture will have a value added to it aside from the artistic and labor value.

I thought I would share the process for making a bronze. This will help you to appreciate the incredible time, labor, and effort that takes place after the sculpture is created. I intend to have a video in the future, but for now, here is a step-by-step process.

1. Making the Mold From An Original Work of Art: This step is by far the most critical. All the detail which appears on the original sculpture must be captured in this mold. The mold (depending on the size of the sculpture) is cut into sections for casting. This can be a harrowing experience, especially for the artist, since any damage to the clay has to be fixed before molding. I generally use someone who is a professional mold-maker and an artist.
2. Making the Wax Casting: Molten wax is poured into the mold to form layers of wax. This wax model is exact duplicate of the original casting. Imagine the detail that can be had from this method - have you ever dropped candle wax on your finger? It contains your fingerprint afterward. Nice detail.
3. Chasing the Wax: The wax is pulled from the mold and hand chased (re-detailed) by a skilled artisan. Although the artisan tries to reproduce the original artwork, each piece may be slightly different from the next. I try to make sure the details are exactly like I first created them, and so I am part of the entire process. I have a purpose in each subtle texture and groove of my sculptures.
4. Spruing: Wax rods (gates) and pouring cup are attached to the wax casting in just the right positions. This will assure a full pour.
5. Casting the Ceramic Mold (Investment Casting): 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 a 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. This ensures a solid mold.
6. Burn-Out: The ceramic shell is placed in a kiln and fired. The shell bakes and the wax is melted (here is where we get the term “lost wax”) from the shell. This creates a hollow ceramic shell mold.
7. Casting: The ceramic shell (mold) is removed from the kiln and immediately the molten bronze is poured into the shell. At the time of pouring, the bronze is 2100 degrees Fahrenheit.
8. Break-Out: After the casting has cooled several hours, the shell is carefully broken away leaving the unfinished bronze.
9. Sandblasting: Any fragments of the ceramic shell are removed by sandblasting. The sculpture is also carefully inspected at this point. This is where one is happy to have selected a good foundry. From here on out, until the patina, the foundry’s skill level is crucial.
10. Assembly: At this time all the pieces of the sculpture are welded together by the skilled craftsman.
11. Chasing: All the weld marks are chased and re-detailed .
12. Glass Beading: This is similar to sandblasting, the glass is extremely fine to ensure an even bronze finish.
13. Polish: The raw bronze sculpture is now hand polished in preparation for the patina.
14. Patina: The bronze is first heated. The patina chemical is hand applied by the skilled artist at my direction. The patina is the coloring you see when you look at a face as compared to an article of clothing, etc. I like my faces to be a certain color, some leave it up to the foundry. No way!
15. Waxing: The wax is hand applied with heat to ensure a beautiful lustrous patina. This makes it shine and also protects it from the elements. I recommend reapplying wax every couple of years if outside.
16. Mounting and Inspection: The bronze is mounted on a marble base or other large landscape stone and is ready for the final inspection, then packaged and shipped to you!