Metal Chasing of "Ascension"

The bronze has been poured then the metal shell smashed off. After it was sandblasted to clean off any lingering particles, they take the sculpture in and begin to weld the pieces back together. Then an artisan known as a metal chaser then works on
burnishing out the weld seams and any some imperfections that they find. Marker indicates areas that they will do some additional work.

 I spent a lot of time at the Base Shop selecting the base (Nordic Green Granite) and how the sculpture will work with the base. We are going to go with a two tier base so that there will be room for the turntable (then the sculpture will rotate smoothly)

The sculpture is looking beautiful and I've mapped out my patina ideas - so once the sculpture has been custom fit to the base and the chasing done - it will be time to patina and affix to the base!

First Bronze Pouring of "Ascension"

Today was the first pouring of bronze for "Ascension"!  The shells had been built up over the hollow wax sections over a period of time. The shells were then placed into the furnace and the wax was melted out - a process referred to as "lost wax".

Next they took special buckets and collected the molten bronze and poured the liquid metal into the now-hollow ceramic shells. Once the bronze cools, they break apart the ceramic shells using hammer and pneumatic tools. After removing the hard shells, the sprues are then cut off using plasma torches.

Once that is completed, the sections of bronze are cleaned up by sand-blasting the last bits of plaster shell residue.

Finally, after the pieces are cleaned up they are ready to be welded back together.

Tomorrow I'll post photos of the sculpt being metal-chased.

Attaching wax sprues & making ceramic shell

Jeanne from Art Castings foundry let me know that the sprues were being added to my wax Ascension today. So I grabbed my camera and drove down through the snow to get some shots of the process. Wendy was working on the piece as I walked into the sprue room. She showed me how she evaluates each section to envision how the bronze will flow into the cavity left by the wax, then creates different sized channels out of wax (sprues) to act as the funnel for the bronze to pour down.

It's amazing how much work and time goes into the creation of each and every bronze. This whole process is created for every one in an edition and also means that no two bronzes are 100% identical.

Once all the wax spruces are in place, Wendy adds a pipe to the bottom of the pour cup and takes to the slurry room and places them on tall poles called 'trees'.

Next John will take each wax section and dip it into a slurry mixture, let it drain a bit then take it to a sand box and shake silica over it. The slurry and silica are built up layer, by layer over a period of 1-2 weeks, creating a hard shell encasing the wax. They are placed on the trees to dry and harden.

Once the shell is complete, it's off to the furnace to burn out all the wax and pour the molten bronze.

Wax pour for "Ascension" Bronze casting

It was quite foggy this morning and I nearly postponed my drive down to Art Castings in Loveland. But, since I'd already filled my travel mug with hot tea and charged up my camera, I decided not to wait and I'm quite glad!

When Jeanne greeted me, she knew just where my work, "Ascension", was in the maze of other sculptor's molds and waxes. They had just poured the first two waxes and Mac was starting to chase them.

In the montage photo:

1) collection of rubber molds inside the mother-mold

2) the mother mold encasing the rubber like a clamshell

3) you can see that the rubber comes out of the shell

4) the mother mold seams together tightly

5) hole where the wax is poured in

Here are some photos of the hollow wax that was poured. Mac is working on taking out imperfections in the wax. He will also fix where the armture came through. When he reaches a certain point in the process, they will call me and I will head down to spend the day doing finish chasing and detailing until I am satisfied before preparing the wax for the bronzing process.




You can see the whole process of making a bronze at the Art Castings site http://artcastings.com/casting-process.htmlhttp://artcastings.com/casting-process.html

First wax pouring of miniature fox sculpture

This is my first time pouring wax in preparation for the lost wax bronze process. I have an old crockpot that I'm using to heat the wax. This wax is something I bought an embarrassingly long time ago and can't remember what kind it is. Karen, at Sculpture Depot, assured me that pretty much any wax will work and different kinds can be intermixed. I thought I'd be really smart and put the block of wax in an old metal can inside the cooker to keep the cooker from getting wax all over it. Nice idea, but it dripped and got wax it it anyway ;-)
I'm using the pour mold (commonly called a dump mold) that I made of my miniature fox (you can see on earlier posts). After melting the wax, I took a small cup, dipped it into the melted wax and poured into the mold. Then swirled the mold around and emptied the wax back into the pot. A layer of wax remained inside. I did this several times to build up layers.
1) crockpot with melted wax in can
2) wax in the mold (I tried tape to secure the mold but it didn't stick very well - rubber bands worked better)
3) the wax mold of the fox - it has flaws and the base would need to be trimmed.
4) I was anxious to see the wax and demolded too soon - the wax was still quite warm and broke.You can see how the swirling of the wax creates a hollow casting.
5) I figured it would take several tries to learn the process enough to get good results. Luckily I can simply melt down the rejects to reuse the wax.
6) Back into the pot for remelting. I tried again that night - but the wax wasn't hot enough so it was a tad lumpy. The results were another imperfect casting so will try again later.

Miniature Fox Sculpture with New Patina

I wasn't satisfied with the first casting and patina of my miniature fox sculpture, so try, try again. This one came out much more to my liking and I earned a good lesson: solid colors show texture and form much better than variegated colors. Especially in such small scale (about 3"). I have a base that I'm preparing so when it's dry we'll see how it looks on a solid wood base.

My next endeavor will be to cast this fox in wax and chase it. I have an appointment with Art Casting Foundry in Loveland, where I'll be having this little guy bronzed!

I'm quite excited about that - I sculpted him with mold-making and bronzing in mind as I want to learn both processes.

Since this patina came out much better, it gave me the urge to work on some of my other sculptures. There were two in particular that I didn't care for how the original patina came out. Since I wasn't happy with the over all look, I decided that I could risk ruining them further by removing the patina and trying a different. It was a good choice - and I will post new photos of them soon.

Lastly, I've been struggling with my photography. On a shoe-string budget, I've been trying to outfit my photo area and have been making loads of test photos. Thank goodness for digital! Back in the day you could photo for a show, send the film off and not find out till a week later that they were awful! But now - Bam! upload the photos and see how bad they are instantly! ;-) Actually, I made real progress this week in getting white balance and lighting to agree - so new photos will be up soon!

Cast sculpture miniature fox

This is the final cast piece from the mold I made of my miniature fox. You can see the original oil-based clay sculpt on my December blog. The instructions and process of how I made the mold are in the previous post.

This was cast using Smooth-On's Smooth-Cast 300 liquid plastic.

This is an easy product that is mixes compounds A+B in equal amounts. The plastic cures in a matter of minutes to a very white plastic. It demolded from the silicone very easily.

The down side is that, well, it's PLASTIC. Not my favorite substance. But this is a learning process . I painted the plastic casting using acrylics to mimic dark stone and the results are fine. I should have done a little more clean-up to the lines where the mold joins together, but for a first try at casting, I thought it came out well.

I could also pour melted wax into this mold, clean up the wax and take it to bronze at some point. We'll see ;--)

Miniature Fox Sculpture mold making

I took the miniature fox that I sculpted in December and made a mold (often called a pour or dump mold). I used Dragon Skin mold-making products by Smooth-ON.

 1). Dragon Skin is a 2-part silicone mold - you mix equal parts of A + B. I also used Liquid Gloves - it forms a barrier to protect your hands from absorbing chemicals or paint - it feels nice, goes on like hand lotion.
2)  I cut the bottoms off of two plastic cups to form a cylinder around the fox sculpture. I put a small bit of clay on the bottom of the fox sculpture to help it stay in place, then put the cups over it and sealed the bottom of the cups to the base to keep the silicone from leaking out.
3)  I also put the whole thing on a small tray in case it leaked - but this time I sealed it well and nothing leaked out.
4) Mixing Parts A + B
5) Poured into the cylinder and curing (left it over night)
6) I took this to class and my instructor, Rik Sargent, helped me to cut the cured silicone on two sides on a diagonal to get the clay out.