Lost-wax bronze casting

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Two predominant methods exist for transitioning from plaster to bronze models: lost wax casting and sand casting, the latter once prevalent in Rodin's era but now quite rare. In both methods, molten bronze is poured into a mold that surrounds a core, which is subsequently removed. This process results in hollow bronze sculptures, reducing weight and costs. Lost wax casting begins with creating a delicate mold, traditionally made from gelatin, which is formed by taking an impression of a plaster or clay model. Once the model is extracted, it is carefully preserved. This flexible mold, supported by a plaster cap, is then filled with a durable material intended to serve as a core. The core’s shape is slightly adjusted to include a bronze thickness and is held at a distance from the mold walls by metal rods. Liquid wax is poured between the core and the mold walls, hardening upon cooling. Following this, the mold is opened and the gelatin mold is cleaned for potential reuse. Rodin's Porte de l'Enfer, designed for a project that remained unfinished, showcases a vast array of shapes with limitless possibilities. His research for the Victor Hugo monument illustrates Rodin's tendency to blend figures, alter dimensions, and adjust spatial positions. In his Balzac project, he moved beyond mere resemblance in favor of a more symbolic representation that challenged public monument conventions. His marble works often draw from mythology while also expressing abstract concepts in a symbolist style, where eclecticism is highlighted by a combinatorial aesthetic. As a renowned portrait artist, Rodin also explored variations on facial expressions. Sharing affinities with the Impressionists, he became fascinated by perceptual phenomena and the way light influences form. At the pinnacle of his career in the late 19th century, Rodin reflected on his work during a major retrospective at the Pavillon de l'Alma, shaping public perceptions of his art.

The wax model, retaining the core, undergoes retouching and is signed by the artist with the print's number and the foundry’s stamp inscribed on it. A network of wax rods is constructed around it, all of which is encased in heat-resistant earth designed to endure the intense temperatures and pressures of molten bronze. The completed casting mold is then placed in a furnace where the wax is melted away. The hollowed wax rods now function as drains, allowing wax evacuation; jets for receiving molten bronze; and vents for air release. The robust mold is then lowered into a casting pit where it receives the molten bronze, which must be poured quickly into the space left by the removed wax. After the bronze has cooled, the mold is broken apart. The subsequent steps include cutting the supply network, disassembling the core, chasing, and polishing the surface. Finally, metal oxides are applied to the bronze, which through controlled corrosion, develop a patina that enhances the work's protective color, manifesting in shades of brown, green, blue, or black.

Wax carving plays an essential role for jewelry makers, enabling them to create wax models that result in exquisite and finely detailed jewelry pieces through the lost wax casting process. Known as cire perdue in French, this casting technique is incredibly versatile, capable of accurately reproducing complex designs in metal, with a rich history stretching back over five thousand years.

The precise origins of lost wax casting are a bit of a mystery, potentially developed independently across various regions, but archaeological evidence indicates its first use dates back to the fourth millennium BC.

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Before the advent of lost wax casting, molten copper was utilized to create relatively simple tools and weapons using basic open or two-part molds made from stone or clay. The innovative shift of first crafting a wax model, around which a clay mold could be formed and heated—hardening the clay shell while simultaneously melting away the wax—allowed for the casting of more intricate metal objects, ushering in a new realm of craftsmanship.

Among the earliest known artifacts produced via this method are decorative copper items discovered in the Nahal Mishmar hoard in Southern Palestine, dated to around 4000 BC. Other ancient lost-wax-cast items—ranging from delicate miniatures and decorative pins to life-sized sculptures—have surfaced worldwide, including in Europe, the Middle East, Asia, Africa, and the Americas.

As lost wax casting spread, various techniques and adaptations emerged. Artisans began to cast items in bronze and gold, while the advancement of hollow casting enabled the creation of affordable hollow objects, and indirect casting opened the door to larger-scale pieces.

The most significant advancements to this traditional technique, however, came in the 20th century. Following initial developments in dental applications, the jewelry industry was revolutionized in 1943 by Danish engineer Thoger Gronborg Jungersen, who patented a method that utilized reusable rubber molds to create multiple wax models without the need to carve each one out individually.

In the modern era, with the rise of CAD and 3D printing, jewelers have access to advanced design and production tools. Yet, hand-carving wax models for lost wax casting enables them to connect with the ancient roots of their craft, as this technique continues to be one of the most precise methods for reproducing intricate metal designs.

If you’re curious about trying your hand at wax carving, read more about our short course Wax Carving for Jewellery here. Our team is here to discuss your requirements regarding Cencho Check Valve. Our experienced sales team can provide guidance to help you identify the best options to meet your needs.