The Foundry.
Once the wax sculptures arrive to the foundry, the designs are attached with sprous and gates to allow for the flow of air, wax and brass.
Next, each piece goes through the lengthy process of 8 dippings in ceramic shell, a combination of silicate powder and slurry.
Once thoroughly layered and dried the pieces are heated in the burn out kiln. While the ceramic shells harden into a durable egglike wall, the wax is simultaneously melted out. The forms are now ready for the pour.
In prepping for the pour, brass ingots are heated in the furnace and brought up to 1724 degrees Fahrenheit.
A designated crucible holds the molten brass ready for the pour.
Protected from head to toe in heat proof gear, the foundry team works in tandem to methodically pour the molten brass into each shell form.
The molten metal is set to cool for hours until the shells can be handled.
With the anticipation of an archaeological excavation, the design is then carefully chiseled out to expose the form within.
Lastly, the design is sandblasted and then once again, meticulously chased with a variety of tools to match the artist’s proof originally designed in wax.
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