Mixed-Media Sculpture Fabrication

We begin with your design and engage you in a detailed discussion of the material strategy: Which areas require structural strength? Which demand fine surface detail? Which will be viewed at close range, and which from a distance? Which must withstand weather and corrosion, and which are intended only for interior display?

What this means for you: we do not rely on intuition or guesswork. We develop a material strategy precisely matched to your aesthetic and functional requirements.

Fiberglass-reinforced plastic (FRP) is one of our core specialties. It is lightweight and strong, and can achieve the fluid, continuous surfaces favored in contemporary sculpture. What this means for you: complex curves, seamless surfaces, and structural strength can all be realized without excessive weight.

Metals—the rigidity of steel, the lightness of aluminum, the warmth of bronze and copper, and the weathered character of weathering steel—are worked by welding, forging, casting, or CNC cutting. What this means for you: whether your design calls for minimalist geometry or a raw industrial presence, metal gives the work a distinctive structural character.

Wood—from the firmness of oak and depth of walnut to the weather resistance of teak and fine grain of maple—is shaped using traditional mortise-and-tenon joinery, modern lamination, or CNC carving. What this means for you: warm, organic, and tactile, wood gives your sculpture an added quality of human intimacy.

Foam and polyurethane serve as lightweight cores for large-scale works or as temporary models. We combine CNC hot-wire cutting with hand shaping. What this means for you: exceptionally large works can be fabricated without dependence on heavy lifting equipment, with controlled costs and shorter schedules.

Resins and cementitious materials—including clear resin, epoxy terrazzo, and ultra-high-performance concrete (UHPC)—are cast, layered, or combined to achieve singular effects. What this means for you: translucency, extremely thin walls, and simulated natural textures become possible where conventional materials fall short.

Your sculpture begins with a clay original, foam model, or digital model—the master from which all subsequent processes proceed.

For works requiring reproduction, we make molds. Where exceptional detail is required, a silicone-rubber facing captures every micron of surface texture and is supported by an FRP or plaster mother mold. Geometric forms may use rigid molds or simple casting molds. Each mold is divided into sections designed for efficient demolding and assembly.

What this means for you: where multiples are required, every edition is consistent; for a unique work that does not require replication, we do not make unnecessary molds. You pay only for what your project needs.

For metal works, we may bypass moldmaking and proceed directly to sheet cutting and welding, tube bending, or precision casting. For wood works, we carve, join, or turn solid timber or engineered laminated stock directly.

FRP lay-up: fiberglass cloth or mat is placed in the mold, and resin is distributed evenly by hand lay-up, spray-up, or vacuum infusion. Resin content is controlled at 50%–65% to achieve optimum strength. Complex shapes are laminated in stages, with demolding openings reserved; after curing, the next section is continued. What this means for you: even the most complex geometry can be realized. We do not avoid challenges; we find engineering solutions for them.

Metal fabrication: steel and aluminum are joined by MIG/TIG welding, bolting, or riveting; bronze and copper may be forged or cast by the lost-wax process; weathering steel receives a controlled pre-weathering treatment to develop its distinctive surface. Large structural elements incorporate internal stiffeners for stability. What this means for you: the work retains metal's elemental power while being carefully engineered to stand securely and withstand the elements.

Wood fabrication: bandsaws, carving machines, and hand tools shape the material. Curved or non-standard components are first roughed out by CNC machining and then finished by hand to preserve the wood's grain and tactility. Large wood sculptures use laminated assemblies or internal steel armatures. What this means for you: machining never erases the natural beauty of the wood—the machine performs the subtraction; the hand provides the defining finish.

Foam and polyurethane fabrication: large surfaces are rapidly formed with CNC hot-wire or resistance-wire cutting, then refined by hand. A rigid coating or FRP skin is applied as a protective layer. What this means for you: large foam sculptures are lightweight and economical, making them well suited to exhibitions, installations, and temporary public-art projects.

Resin and cement casting: formulated resin or UHPC slurry is poured into the mold and vibrated to release air bubbles, then cured, demolded, and finished. Pigments, metal powders, or lighting elements can be embedded in clear resin. What this means for you: material possibilities expand almost without limit—nature can be simulated, or textures unknown in nature can be created.

The components are assembled into a complete sculpture. Metal parts are welded and ground; wood components are joined and dressed; mold seams and pinholes are removed from FRP and resin parts; and foam components receive a sealed surface.

Finishing is tailored to each material:

What this means for you: your sculpture looks exactly as intended—whether defined by the cool severity of metal, the warmth of wood grain, or a smooth seamless surface—and retains that appearance over time.

Large-scale and outdoor works incorporate embedded steel “skeletons” or anchor bolts to ensure long-term stability. Depending on site conditions, installation may involve lifting, sectional joining, or on-site assembly.

What this means for you: your work takes its place exactly as it should—safely, securely, and precisely.

• FRP and resin: after sanding, surfaces may be sprayed with faux-bronze, faux-stone, painted, metallic, matte, or high-gloss finishes—whatever the design requires. Outdoor works receive specialized UV-, acid-, and alkali-resistant coatings.
• Metal: options include hot-dip galvanizing for corrosion protection, controlled pre-weathering of weathering steel, accelerated verdigris patination of copper alloys, sandblasting, brushed finishes, baked enamel, and electroplating.
• Wood: depending on the exhibition environment, treatments include hardwax oil, clear varnish, exterior preservative coatings, or an exposed natural texture.
• Foam: a protective hard-shell coating is applied before the final finish.