1.The form is firstly sculpted in clay.
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2. The form then needs a rubber mould made, a master mould allows hollow wax casts to be made in order to be able to reproduce limited editions. If complex, a mould may need to be made in several sections.
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3 The next stage is to paint wax onto the rubber and then pour molten wax into the mould pouring back in and then out again which leaves a residue of wax approx 6mm thick.
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4. A tree of runners and risers is then applied. Runners provide an entrance for the molten bronze. Risers provide an exit for air when molten bronze is poured through the runners.
5. Investing involves covering the wax with a ceramic slip, at first this painted to make sure all the surface details are reproduced in the bronze and free from air bubbles. The wax is then dipped in more ceramic slip and allowed to dry. The process is repeated over several days until enough bulk is formed around the wax for it to resist the high temperatures of the kiln.
6.
The next step is firing the mould in a kiln up to a temperature of 700 degrees
C; this burns out the remaining wax, which in turn creates a void. Once out
of the mould it is taken out of kiln and place it in a pit.
7. Now the bronze can be poured into the void, left by the wax in the mould.
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8. When cold the mould is gently knocked open to reveal the raw bronze.
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9.Metalworking can now begin, this stage calls for a high attention to detail, and this can be a very laborious process trying to repair all the casting defects through welding and bronze chasing.
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10.
Then the final polish is needed to buff the surface, or patination* if this
is
to be used for the final surface.
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*
When Patination is used the process involves a chemical colouring of the surface
of the bronze, which is
achieved by first heating the metal using a blowtorch to which oxides are then
applied to the bronze with a brush.