In a nutshell, this is how we make sculpture and fine jewelry. The “lost wax” casting process, goes something like this:

From a model sculpted of clay, metal or wax, Malcolm creates a mold for reproduction. Molten wax is injected into the mold and allowed to cool, leaving a wax pattern, which is checked for detail and completeness.

The wax pattern is “tree'ed up,” or attached to a base using additional wax for hold and support. A stainless steel flask (like an open tin can, or tube) is placed around the wax parts.

We mix and pour “investment” (plaster, with material suited to take extreme heat) over the wax parts in the flask. The contents are then vacuumed in a chamber to release the air bubbles. Once set, the flask base is removed, leaving only the investment, and the wax patterns suspended in the investment, inside the flask.

After drying the investment for 2-4 hours, we slowly “burn out” the flask in an oven overnight, at temperatures reaching 1300 degrees F, eliminating the remaining wax. With the flask temperature reduced to 900 plus degrees F for casting, Bronze, Silver or Gold metal is melted in a crucible. At just the right moment, the metal is cast into the flask, filling the space left from the burned out wax pattern.

After the metal casting is broken out of the flask using a waterjet tool, the cast parts are cutoff from the metal tree, sandblasted, and prepared for finishing.

Next is “deburring,” or grinding and sanding, followed by polishing, or when flat surfaces are involved, “lapping.”

Plating of Gold or other metals follows if the job requires, then final assembly, setting of stones, mounting to base, and voila.

Easy as 1, 2, 3....4, 5, 6, 7, 8, 9, 10, 11, 12.