How are bronze statues made today?

Creating bronze statues today involves a blend of traditional techniques and modern technologies. Here’s an overview of the process:

1. Design and Model Creation:

   - Concept Development: Artists start with sketches and small-scale models (maquettes) to conceptualize the design.

   - Full-scale Model: A full-scale model is then made, typically from clay, wax, or other materials. This model serves as the master pattern for the final bronze sculpture.

2. Mold Making:

   - Flexible Mold: A flexible mold is created from the full-scale model using materials like silicone rubber or plaster. This mold captures every detail of the original model.

   - Mother Mold: To support the flexible mold, a rigid outer shell (mother mold) is often made from plaster or fiberglass.

3. Wax Model:

   - Wax Pouring: Molten wax is poured into the flexible mold, forming a hollow wax replica of the original model once it cools and hardens.

   - Wax Chasing: The wax replica is carefully inspected and any imperfections are corrected by “chasing” (smoothing and refining).

4. Spruing and Gating:

   - Wax Sprues: Wax rods (sprues) and gates are attached to the wax model to create pathways for molten bronze to flow and for gases to escape during casting.

5. Ceramic Shell or Investment:

   - Dipping: The wax model with its sprues is repeatedly dipped in a ceramic slurry, then coated with sand, and allowed to dry between coats. This forms a hard ceramic shell around the wax.

   - Burnout: The ceramic-coated model is placed in a kiln where the wax is melted out (lost wax process), leaving a hollow ceramic mold.

6. Bronze Pouring:

   - Bronze Melting: Bronze ingots are melted in a furnace until they reach a temperature of about 1,200°C (2,200°F).

   - Casting: The molten bronze is carefully poured into the ceramic mold, filling the void left by the wax.

7. Shell Removal and Finishing:

   - Shell Breaking: Once the bronze cools and solidifies, the ceramic shell is broken away, revealing the rough bronze casting.

   - Chasing: The bronze animal sculpture undergoes chasing again to remove any imperfections, sprues, and to refine details.

8. Patination:

   - Patina Application: Chemicals are applied to the bronze surface to create the desired patina (coloration), which can range from traditional greens and browns to more modern hues.

   - Sealing: The patina is often sealed with wax or lacquer to protect the finish.

9. Mounting and Installation:

   - Base Preparation: The sculpture is mounted onto a base, which can be made of various materials such as marble, granite, or wood.

   - Installation: The final piece is installed at its designated location, which might involve anchoring it securely if it is a large outdoor sculpture.

While the fundamental steps remain rooted in ancient techniques, modern advancements such as digital sculpting, 3D printing, and more sophisticated materials for molds have improved precision and efficiency in bronze statue making.