What is the Production Process of Bronze Sculpture？——Bronze Cast from Aongking

step 2: Material Selection and Preparation:

Choosing the right copper materials is crucial for achieving the desired aesthetic and durability. Aongking selects high-quality copper sheets or blocks based on the specific requirements of your sculpture.
Before shaping begins, the copper sheets are meticulously prepared. This includes cutting them into appropriate sizes and possibly annealing them to soften the metal for easier manipulation.

step 3: Modeling and Prototyping:

To translate the approved design into a tangible form, Aongking often creates a prototype or small-scale model. This step allows us to test proportions, details, and overall aesthetics before proceeding with full-scale production. Your feedback on the prototype is valued, and any necessary adjustments are made to ensure the final sculpture reflects your vision accurately.

After the production of the design scheme and clay sculpture (refer to the production of the model). Mold turning before casting sculpture: After the clay sculpture is finished. Before casting the bronze sculpture. We need to turn a silicone mold from the mud film. After the silicone mold was completed, the bronze sculpture was ready to be cast.

step 4: Fabrication and Shaping:

4.1 Skilled artisans utilize a variety of techniques to shape the copper sheets into the desired form. These techniques may include hammering, folding, and welding, each performed with precision and attention to detail.

4.2 Wax-type filling system: the melted paraffin wax is poured into the silicone mold that has been made. Let the paraffin cool down. Remove the molded wax mold. Then the wax mold is trimmed.

4.3 Shell making: there are two kinds of shell making and mold turning. One is precision casting (briefly). The other is made of resin sandbox. Aongking will choose according to the situation of the two kinds of turning schemes. Generally speaking, we choose precision casting for small sculptures or sculptures with complex details. The sandbox production is generally suitable for simple without too complex details and the surface of the sculpture is smooth.

4.4 After the candidate turns over the plan, pour the wax mold with mortar, and repeat the pouring until the mortar completely covers the wax mold to a certain thickness. Dry the wax mold wrapped in mortar. Then put the shell in the oven and heat it until the paraffin melts. This is the lost wax method of traditional casting.

Details of the lost wax method:

          4.4.1 In lost wax casting or investment casting, sculptors first need to create a full-size sculpture model, usually using non-drying oily clay, such as rubber clay models used for making small sculptures or sculptures that require long-term production (water-based clay must prevent drying), water-based clay used for making large sculptures or sculptures that need to capture posture characteristics – these characteristics not only convey the movements of the sculpture subject but also convey the movements of the sculptor. 

         4.4.2 The mold is made of a clay model, which can be made into a mold with gypsum, or can be made of flexible gel or similar rubber-like materials, and stabilized with several gypsum jackets. This type of mold is usually used to make gypsum master molds for further refinement.

        4.4.3 Once the production mold is obtained, wax is cast from the mold (large sculptures are hollow). For hollow sculptures, cast the core into the void and hold it in place using the same metal pin as cast (after the wax has melted). Add one or more wax gates to guide molten metal into the sculpture – typically liquid metal is guided from the pouring cup to the bottom of the sculpture, and then filled from bottom to top to avoid splashing and turbulence. Additional gates can be guided upwards in the middle position, and various ventilation openings can be added to trap gas. 

       4.4.4 Then place the complete wax structure into another mold or shell and heat it in the kiln until the wax is used up and all free moisture is removed. Then quickly fill the embedding material with molten bronze. Removing all wax and moisture can prevent liquid metal from being explosively ejected by steam and vapor from the mold.

4.5 Casting and polishing: The copper ingot is converted into copper water at high temperatures. Pour copper water into the finished shell or sandbox. And then clean the riser grinding.

4.6 Splicing forming: such as casting cold to go. Put the polished bronze pieces together. Through the welding process. It is to make all castings into a complete whole. Once this is done, we should be able to see the general shape and appearance of the cast copper sculpture.

lost wax bronze casting

step 5: Detailing and Surface Treatment:

Intricate details and textures are meticulously added to enhance the sculpture’s visual interest and depth. Artistic techniques such as chasing, engraving, or applying patinas are employed to achieve desired surface finishes and coloration. Surface finishes, whether polished to a high sheen or textured for a more organic look, are carefully applied to complement the sculpture’s design and environment.

Product casting dressing and treatment: for welded castings. The surface is extremely rough. Copper products after welding also need to be sandblasted, cleaned, grinding, shaped, machined, polishing, and other processing.

After final polishing, corrosive materials can be used to form copper green, which can control the color and smoothness to a certain extent.

step 6: Assembly and Integration:

If the sculpture consists of multiple components, they are seamlessly integrated using advanced welding or soldering techniques. This ensures robust construction and a cohesive appearance that aligns with the original design concept. Rigorous quality checks are conducted throughout the assembly process to maintain our commitment to craftsmanship and ensure each sculpture meets our exacting standards.

Surface effect treatment and protection of casting sculpture: coloring is usually divided into cold coloring and hot coloring. According to the author’s requirements on the surface of the copper sculpture color, the cast copper surface treatment required effect, so that the shape and color achieve perfect unity.

Oiling and sealing wax: after cleaning the welding joint and coloring the surface. The next is to cast a good sculpture surface oil, and sealing wax. Oiling, and sealing wax steps can make the sculpture surface for a long time to maintain a new feeling.

step 7: Final Inspection and Finishing:

Before leaving our workshop, each sculpture undergoes a comprehensive final inspection. This includes meticulous examination of details, finishes, and overall quality to confirm it meets both our rigorous standards and your specifications.
The sculpture is carefully cleaned and prepared for transport, ensuring it arrives at its destination in pristine condition.

step 8：Delivery and Installation:

We coordinate secure transportation of the sculpture to your designated location, handling logistics to ensure safe delivery.
Upon arrival, our team provides expert guidance and support for the installation process, ensuring the sculpture is positioned and displayed to maximize its visual impact.

step 9: Documentation and Your Care:

Alongside the sculpture, we provide documentation such as certificates of authenticity and care instructions. This helps preserve the artwork’s value and longevity, offering peace of mind for your investment. Our commitment to your satisfaction extends beyond delivery. We offer ongoing support and advice to ensure your sculpture continues to captivate and inspire for generations.

installation of sculptrue

productive process of casting