Bronze casting dates back to the ancient Chinese and the process has largely remained unchanged for thousands of years.  The sculptures are cast using the traditional lost-wax method.  Today the process is improved by mechanized tools but the process remains the same.

A steel armature is fabricated that will function as a ”skeleton” to hold the weight of the clay.
The piece is sculpted using an oil based clay.
The piece is worked and reworked until both the artist and client are pleased.
The finished life-size sculpture and small model
Thin sheets of metal are used to divide the sculpture in to a predetermined number of sections.
A latex rubber is applied to the clay sculpture.  Five to six coats are used to build up a sufficient thickness.
The molds are backed with plaster, which will give rigidity and support to the rubber.
The plaster pieces are removed and the latex is cut down the center to create a two section mold.
A finished set of Molds
The molds are coated with wax to create a copy of the clay original.
Wax is poured in, the mold is rotated to evenly coat, and the excess wax is poured out. This will create a hollow replica.
A finished wax being removed from the mold
One finished wax piece
The pieces are touched up and wax runners and a wax cup are attached.  The cup and runners will later act as funneling system to enable the bronze to reach the piece.
The pieces are coated in a liquid ceramic and allowed to dry.  This will be repeated seven to eight times to build a thick ceramic shell.  The shell becomes another mold.
Finishing the first coat
The piece is next coated in sand. This will help dry it quicker and add mass to the ceramic.
The ceramic is chipped away from the bottom of the cup gaining access to the wax.  The piece is heated and the wax melts, leaving a hollow ceramic shell.
The mold is now hollow and ready for bronze to be poured in.
20 lbs. bronze ingots will be melted and poured into the shells.
The bronze is melted in a crucible in a furnace to over 2000 degrees.
The ceramic shell is also heated, to prevent them from shattering from the shock of the molten bronze.
The shells are removed from the oven and placed in a sand filled box with the cup facing up.
The cup acts as a funnel and the runners carry the bronze to the piece.
Once cooled, the ceramic shell is chipped away. Then the cup and runners will be cut off.
A finished set of bronze pieces ready to be reassembled
Using heli-arch welders the bronze pieces are welded back together.  The sculpture is ground and polished to create a seamless finish.
The sculpture is heated and treated with chemicals that oxidize the bronze changing its color to the desired effect.
The finished piece is not only beautiful but strong, durable and able to last generations!