The PROCESS OF CREATION
How Do We Create
a Bronze Garden Sculpture?
What does it take to transform an idea, an illustration; a character from a beloved children’s story, into a stunning bronze garden sculpture? Let us take you on a journey through the meticulous process that breathes life into each handcrafted piece in our collection.
“Why,' said the Dodo, 'the best way to explain it is to do it!”
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1. Creating the original model
The first step is to create the original model; a representation of the final form, typically sculpted from clay or wax. In ancient times, wood or basic clay was often used, but modern artists use a range of materials to shape intricate lines and detail. Every feature must be carefully considered at this stage, as the model is the foundation for everything that follows.
2. Crafting the mould
Once the model is complete, the next stage involves capturing its form in a mould. Made from ceramic or rubber, its purpose is to faithfully reproduce every intricate detail of the original design. For complex or large sculptures, multiple moulds may be created to ensure that each section is carefully preserved. The mould is then hardened, locking in the sculpture’s form and setting the stage for the next transformative step.
3. A wax replica
The traditional lost-wax casting process involves pouring molten wax into the mould, forming a hollow wax version of the sculpture. Once cooled and removed from the mould, the wax model is meticulously inspected. Imperfections, such as air bubbles or uneven surfaces, are corrected with precision tools to ensure that the sculpture’s detail is flawless before moving forward.
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4. Building the ceramic shell
With the wax model ready, the process of creating a ceramic shell begins. The wax sculpture is repeatedly dipped into a liquid ceramic slurry, followed by layers of fine sand. This builds up to form a robust ceramic shell capable of withstanding the intense heat of molten bronze. Each layer is carefully applied and dried, with up to 10 layers being added to create a strong, heat-resistant mould.
5. The Lost Wax stage
Once the ceramic shell is complete, it undergoes the transformative lost-wax stage which gives the process its name. The ceramic shell is placed in a kiln, where the heat melts away the wax, leaving behind a hollow cavity inside the hardened shell. This step is where the wax is "lost," creating the negative space that will later be filled with molten bronze. The result is a perfect void in the shape of the original design.
6. Pouring molten bronze
Next, molten bronze – heated to an incredible 1,200°C (2,200°F) – is poured into the hollow ceramic mould. The liquid bronze flows into every crevice, capturing even the tiniest details left by the wax model. This stage sets the sculpture’s final form in bronze, and, once the mould is filled, the bronze is left to cool and solidify, completing the material transformation from wax to metal
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7. Removing the ceramic shell
After the bronze has fully cooled, the ceramic shell is carefully broken away to reveal the rough bronze sculpture within. This delicate step requires great care, as the bronze must be extracted without damaging the fine details of the piece.
8. Refining the sculpture
At this stage, the raw bronze sculpture undergoes “chasing,” a process of refinement and detailing. Any imperfections left by the casting process are meticulously removed, and individual parts of the sculpture are welded together if necessary. The surface is polished to ensure a flawless finish, with every line and texture brought to life.
9. Applying patinas
The next step is the patination process which gives the sculpture its unique colour and texture. Through a series of chemical treatments, the bronze is transformed, with hues ranging from warm golds and rich browns to deep greens and even blues. Heat is often applied during this process to create vivid, lasting effects. The patina serves to enhance the sculpture’s appearance and protect the bronze itself, ensuring it will endure for generations.
10. The final stages...
Here, any last imperfections are removed, and the surface is given a final polish to highlight specific features. The result is a stunning, handcrafted garden sculpture that embodies the artistry, craftsmanship, and the timeless beauty of bronze.
Explore the magic of bronze
Here at Robert James Workshop, each bronze sculpture is a love letter to the enduring stories and characters that inspire us. From the enchanting world of Alice in Wonderland to the warm-hearted bucolic charm of Beatrix Potter, our collection has something to transform your garden into a storybook of its own.
If you’d like to find out more about our bronze garden sculpture range please do get in touch.