Metal Casting

Your sculpture begins as 3D data or an original form modeled in clay, wax, or plaster—the first material crystallization of the artistic intent. Every line and every texture carries your expression.

We take a mold from the original model, then inject wax into the mold to produce a wax pattern identical to the original. What this means for you: the fidelity of the final casting depends entirely on this stage. We treat your original work with the respect it deserves.

Our wax-pattern finishers then work under intense light with specialized blades, removing every millimeter-scale imperfection from the wax surface. A single area of intricate ornament may require an entire day. What this means for you: facial expressions, the flow of drapery, and textures you spent weeks refining—every detail is carried faithfully into the casting. We do not “interpret” your work; we reproduce it faithfully.

The finished wax pattern is attached to a gating system, repeatedly dipped in a specially formulated slurry, and stuccoed with refractory sand—six to eight coats in all, progressing from fine to coarse aggregate. The thickness of every layer must be controlled precisely: too thin, and the shell cannot withstand the impact of high-temperature molten metal; too thick, and gases cannot escape properly, causing porosity in the casting. What this means for you: this invisible “armor” protects your sculpture throughout the pour. Our artisans have spent decades mastering the feel of each dip and the correct timing of every coat.

Once complete, the ceramic shell must air-dry naturally for five to seven days. Temperature and humidity are monitored throughout; even a hairline crack can undo all the work that came before. What this means for you: patience at this stage prevents regret at the next. We never sacrifice this protective process simply to accelerate a schedule.

The dried shell is heated to 150–200°C to remove the wax. A perfect negative cavity remains inside the shell—hence the term “lost-wax casting.”

Meanwhile, the shell is reheated to 800°C, while the bronze is melted above 1,100°C and poured as liquid metal. Our foundry masters judge color and temperature by eye: “When the molten metal shines like a mirror and fine ripples appear, it is ready to pour.” The metal is then poured steadily into the shell in one continuous, uninterrupted operation. What this means for you: any hesitation during the pour can cause cold shuts or incomplete filling. Our team has cast thousands of sculptures—they know exactly when and how to execute this critical action.

After cooling, the ceramic shell is carefully knocked away to reveal the raw casting. Sprues and risers are cut off, followed by grinding and polishing. What this means for you: this is the stage at which the surface character of your sculpture begins to emerge. Depending on your requirements, we then apply chemical or physical patination, painted finishes, electroplating, gold plating, or traditional fire gilding. Each effect relies on specialized chemical formulations and decades of accumulated experience.