Sculptors

Bronze Casting Sculpture 

At The Crucible Foundry, we specialise in bronze casting, combining traditional craftsmanship with modern techniques to create high-quality sculptures and functional bronze pieces. The casting process consists of four key stages: mould making, wax casting, investment and firing, and final finishing.

1: Mould Making in Silicone Rubber

The first step in the bronze casting process is creating a mould of the original sculpture. Silicone rubber is used to ensure that even the finest details are captured with exceptional precision. This flexible material allows for easy removal while maintaining the integrity of the original artwork. For larger sculptures, the mould is built in sections and reinforced with a fibreglass jacket, ensuring structural stability.

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Stage 2: Wax Casting & Retouching

Once the silicone mould is complete, it is used to produce a wax replica of the original sculpture. Molten wax is carefully poured into the mould and allowed to cool, forming a hollow wax version of the piece. This wax cast is then meticulously hand-retouched to remove any imperfections and ensure it is an exact match to the original artwork.

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Stage 3: Treeing, Investing & Firing

At this stage, the wax replica is prepared for the casting process:

• Treeing (Spruing): Wax rods, known as sprues or runners, are attached to the sculpture. These create a network of channels that will later guide the molten bronze into the mould while allowing trapped air to escape.

• Investing: The wax model is then coated in a ceramic shell and left to dry. This shell forms a hard, heat-resistant mould.

• Firing (Lost Wax Process): The ceramic shell is placed in a high-temperature kiln, where the wax inside melts and drains away. This step leaves a negative space inside the ceramic shell, creating a cavity that will later be filled with molten bronze.

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Stage 4: Bronze Pouring & Final Finishing

With the ceramic shell now ready, the bronze is melted in a crucible at 1,200°C. The molten metal is carefully poured into the prepared mould, filling the negative space left by the lost wax. Once cooled and solidified, the ceramic shell is broken away to reveal the raw bronze casting.

To complete the sculpture, our craftsmen carry out chasing and finishing:

• The cast is cleaned and blasted to remove oxidation.

• The runners and sprues are cut away, and any separate sections are welded together.

• The bronze is polished and refined, restoring surface details and ensuring a flawless finish.

• A final patination process is applied using heat and specialist chemicals to achieve the desired colour and texture.

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At The Crucible Foundry, we specialise in precision bronze casting, delivering exceptional craftsmanship for both fine art sculptures and functional bronze works. With a team of highly skilled artisans and a commitment to excellence, we ensure that every project meets the highest standards of quality, durability, and artistic integrity.

We  invite you to contact us to discuss your project in detail.