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The work begins with the creation of a scale model in wax. This determines the pose and gesture, and provides the pattern for the armature which supports the full scale figure. The armature is made of welded steel and aluminum. Foam blocks are attached and carved down to fill out the armature to within an inch or two of the eventual surface.
A thick layer of plasteline clay is then laid up over the armature, and the most demanding part of the task begins. The modeling progresses through stages: The antatomy has to first be established, then the drapery, then the surface details. In portraiture, resemblance to the subject is a major preoccupation, and is addressed through all phases.
When the modeling is complete, the original is sectioned into pieces, and rubber molds are made from which hollow wax castings are produced. The waxes are then dressed, and wax bars are attached to allow channels for the molten metal to enter and gasses to escape. These wax patterns are then invested in a fireproof material (ceramic or gypsum) to create a mold capable of accepting the molten metal. When the investments are then fired, the wax melts away, leaving a void which is the exact image of the pattern that has now been burned away. The bronze is melted and poured into this void. When it has cooled, the investment is broken away.
In most cases, the sculpture will have been cast in pieces. Each part now must have the channels (sprues) removed and be cleaned. The sections are then welded back together, and the welds are ground and filed (chaised) until they are hidden. The completed piece is then cleaned again, and chemicals are applied to give the metal its final color.
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