From Clay to Bronze
The Clay OriginalThe concept is first sculpted completely in an oil-based clay.
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Silicone Coating
Several layers of silicone rubber are brushed onto the clay until it is 1/4 to 3/8" thick.
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Creating the Mold
A plaster support is built around the silicone. This mold is filled with wax.
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Wax Casting
The wax is dipped in slurry to create a shell on the exterior. The wax is poured out and the shell is filled with molten bronze.
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The Final Touches
Once the bronze cools down, the shell is chiseled away and final details can be perfected.
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Concept to Finish
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When bronze is the desired end product, Tim uses oil-based clay to make the original. Oil-based clay never dries, and holds detail extremely well. Once the original is complete, several layers of silicone rubber are brushed onto the clay until it is 1/4 to 3/8 inches thick. After the molds are set, they are taken apart and the original is removed. This leaves an exact "negative" of the original.
A support mold made of plaster or epoxy is then built around the silicone to help it keep its shape. The next step in the process is to have several layers of wax poured into the mold. The result is a wax replica of the original which will then be given to the foundry for casting. The wax is then repeatedly dipped in slurry which creates a hard shell. The shell is heated, causing the wax to melt out. While the shell is hot, bronze which has been heated to over 2000 degrees is then poured into the empty shell. After the shell is chiseled away, the piece is reconstructed if necessary, sandblasted, and any detail that was lost is engraved back into the metal. The final step is the patina process. |
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