About the Lost Wax Process
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Great Lakes Art Studio casts sculptures using the Lost Wax Ceramic Shell Process.
First, the artist creates the original sculpture, usually in wax or clay. Then the process of turning the original concept into a limited edition bronze begins.
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The first mold, also called the "mother mold," is made directly from the original sculpture, using coats of liquid rubber or silicon backed with plaster or fiberglass. Hot wax is poured into this mold and allowed to cool, producing a hollow copy of the original sculpture. This wax duplicate is carefully removed from the mold, inspected, and any flaws are painstakingly removed or "chased" by hand. A wax cup and sprues are attached which will channel the molten bronze into the sculpture.
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The second mold, a rigid ceramic shell, is formed by dipping the wax duplicate repeatedly in a vat containing liquid slurry and coating it with silica sand. This takes several days in order to provide ample drying time between each of several coats. The dried ceramic shell is then placed in a kiln to melt out the wax and harden or "fire" the shell.
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Molten bronze is poured into the cup of the hollow mold, flowing through the sprue channels and into the spaces left behind by the lost wax. After the bronze cools, the ceramic shell is carefully chipped away, the pouring cup and sprues are removed, and the piece is ready for finishing. Then the process of welding together, "chasing" out imperfections, and restoring the original texture begins.
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The last step is patina application, the coloration of the finished bronze through the application of heat and chemicals. This produces a permanent color and finish called a patina and completes the transformation of the sculpture into an enduring work of art. All finished pieces receive our foundry mark, a stamp ensuring quality casting.
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About the Patina Process
When metal is exposed to the elements, over time a "tarnished" or oxidized surface results. In the foundry, the patina application process accelerates the oxidation process through heat and chemicals. Various techniques in the application of wet chemicals create a broad range of textures and colors on bronze, copper, brass, and aluminum. The thickness of the application and the process in which a patina is brushed, sprayed, dropped, trailed, or sponged onto the metal determines the appearance and overall tone of the piece.
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At Great Lakes Studio, we pay particular attention to the surface of our pieces, as the finish is one of the most important elements in any work of art. Artists can choose from hot and cold patinas, special waxing and painting finishes, and a wide assortment of colors such as the traditional cupric greens to turquoise, black, or the non-traditional reds, blues, and others.
Our goal is to give the artist the flexibility of desired color and effect. We also specialize in faux finishing using special techniques to give a textured or patterned finish.
Mounting, Delivery and Installation
Proper construction of appropriate bases and special mountings all completed, delivered, and installed in collaboration with architects and engineers.
Conservation and Maintenance
Services are available to restore and preserve indoor and
outdoor sculptures.
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