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DECKER STUDIOS CASTING PROCESS
 
MOLD MAKING:
Once the original sculpture has been completed, a plaster mothermold and a negative rubber mold are made of the piece.
WAX CASTING/FINISHING:
The original sculpture is taken out of the mold and the mold is then reassembled. We then pour wax into the empty space, resulting in a positive mold.
It is then cleaned and gated.
CERAMIC SHELL APPLICATION:
The wax is then ready for shell application. Where it is dipped in a slurry and sand is then applied to the piece. The piece is then left out to dry. This process is repeated until a strong outer shell is created (about 1/4" to 1/2").
BRONZE CASTING:
Next the wax is burned out of the shell (leaving a negative space in the ceramic mold). The shell is then placed in a kiln where it is heated and brought up to temperature. Simultaneously, the bronze is also brought up to pouring temperature. The molten bronze is finally poured into the negative ceramic mold. Thus creating a positive bronze sculpture.
METAL FINISHING:
When the Bronze has cooled off enough to be handled, the shell is divested (broken off), the gates are cute and the sculpture is sandblasted, then chased (cleaned up).
PATINATION:
Once the Bronze sculpture mirrors the original, the piece goes through a chemical coloring process, called Patina. This can be applied either hot or cold, depending on the colors the artists specify. After the patina is applied, the piece is waxed, and ready to go.
 
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