bronze bunny rabbit statue lost wax brass in uk foundry

Casting

We have an long established reputation as a major fine art casting specialist.  We produce an extensive range of brass castings, including decorative hardware, lighting, furniture mounts, finials and clock parts.

We are also able to make bespoke items and past projects have included castings as various as cathedral lecterns, sculptures, newel posts and other hardware for listed buildings and newly deigned spaces. From a client’s sketch, we created the cast bronze hares shown above for a project in Tokyo. An inspired design concept, they are to be used as touch sensitive buttons controlling an elevator.

Using lost wax casting and sand casting processes, we have established ourselves as producers of castings to the highest standards of craftsmanship.

Sand Casting Specialists

Sand casting offers an excellent way in which to reproduce your desired object many times over through a fast and effective process. Our bespoke sand casting service offers the full design and casting process –  including pattern making if an original is not available to copy – through to final polishing and finishing. Detail retention is good with this method but there are limitations in respect of the shapes and profiles which can be cast in sand. For more complex shapes with finer detailing we would recommend the lost wax process as described below.

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Sand casting moulds

Lost Wax and Investment Casting Specialists

LOST WAX BUT NOT A LOST ART

We are one of the few remaining foundries in the UK that still casts using the lost wax
process.

This method of casting originated in India nearly 5000 years ago and the process is
capable of producing very accurate multiple castings which retain virtually all the detail
of an original item or pattern, irrespective of shape. The process, which is fairly simple in
theory but considerably more complex in correctly maintaining the correct procedures and
practices, begins with making a flexible rubber mould of the object and pouring molten
wax into it.

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Handmade pattern and matching silicon two part mould

 

Wax Tree Services

Finial waxes taken from the mould and mounted on a tree

When set, the solid wax model is taken out and chased to remove any moulding marks and imperfections. Several copies are carefully attached to the branches of a wax tree using gentle heat to the stems and the completed assembly is inverted and placed in a cylindrical flask.

After pouring in a special plaster solution, the cylinder is baked in a kiln for severalhours to solidify the plaster and to melt the wax, which runs out through the branches and trunk. Now, the solid plaster block has a hollow centre which taking the precise form of the tree.

Flask Edited

 

Flask Top Edited

Flask prepared for pouring in plaster investment

 

Molten brass or bronze is poured into this cavity and when cooled, the plaster is broken
and washed off to expose the metal casting. The individual decorative pieces are then
cut off the branches so that they can be fettled, polished and patinated or plated in one
of our twelve decorative finishes. Every stage requires precise control with nothing left to
chance. It is this attention to detail that results in the high quality castings for which we
are renowned.

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Brass casting of finials on tree

 

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Finials (L-R) linished, polished and plated in satin nickel. The necks have been machined

separately and soldered in place

 

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Finials ready for packing and shipping