Foundry

Lost wax process in the creation and finish of bronze pieces of art

The “lost wax process,” also known as cire perdue, is an ancient method used to cast metal, especially for creating bronze sculptures. This technique allows artists to turn a clay model or an original design into a detailed and durable metal sculpture. Here’s how the process works, step by step:

Create the Clay Model
The process begins with an artist creating a detailed sculpture or image in clay. This model serves as the prototype for the final bronze piece.
Mould the Clay Model
Once the clay model is complete, a mould is made around it. Typically, the mould is made from a material like plaster, but sometimes a more flexible material like silicone is used. The mould is built up in layers, and it completely surrounds the clay model. After the mould hardens, the clay inside is carefully removed (or “lost”), leaving behind a hollow space that mirrors the original clay sculpture.
Wax Coating
After the clay is removed, the next step is to coat the mould with a layer of wax. This layer is carefully applied to recreate every fine detail of the original sculpture. The thickness of the wax coating depends on the desired final thickness of the bronze sculpture. The wax layer is then allowed to harden.
Create a shell
The wax-coated model is then covered with a fine, heat-resistant material like a mixture of sand, silica, or other materials to form a solid shell. This shell is built up layer by layer, with each layer being hardened or dried. The shell needs to be thick enough to withstand the heat of the molten metal.
Melt and Remove the Wax
Once the shell has hardened, the whole structure is placed in a kiln or furnace and heated to melt the wax inside. The wax flows out of the shell, leaving behind a hollow cavity in the shape of the original clay model. This step is where the “lost” part of the process happens—the wax is lost forever, and this is where the term “lost wax” comes from.
Pour the bronze
After the wax has been removed, the mould is preheated to ensure it can handle the molten bronze without cracking. The bronze is melted in a furnace and then poured into the hollow mould. The molten metal fills the cavity left by the wax, taking on the shape of the original clay sculpture.
Cooling and Shell Removal
After the bronze has cooled and hardened, the outer shell is broken away, revealing the bronze sculpture inside. Any remaining imperfections are smoothed out, and the sculpture is cleaned.
Finishing Touches
Once the sculpture is fully cast, it is often polished, engraved, or patinated (treated with chemicals to change the colour of the bronze). This final touch adds detail and texture to the surface, giving the sculpture its final appearance.

The lost wax process allows for the creation of highly detailed and intricate metal sculptures, as the mould captures all the fine details from the original clay model. It’s a traditional and highly respected method of metal casting that has been used for thousands of years, especially in the creation of bronze statues and artwork.

Foundry

Lost wax process in the creation and finish of bronze pieces of art

Create the Clay Model

Mould the Clay Model

Wax Coating

Create a shell

Melt and Remove the Wax

Pour the bronze

Cooling and Shell Removal

Finishing Touches

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About Jenny Huggett – Sculptor

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