The sculpting process begins with the armature. This is the skeleton or rough outline of the piece and is the initial form. The armature is first composed of a steel frame and soft, pliable wire, filled out with styrofoam and other soft materials. It is constructed on a wooden platform base and placed on a revolving pedestal.
After the completion of the armature, I start to bring the shape more to life by using clay with the proper consistency and getting the figuration of the piece started. Clay and wax sculpting is 80% add-on and the rest take away. It takes weeks to get the right shape, movement and articulation correct. The piece is constantly changing under construction as the angles of observation changes. When the piece is completed it goes into the next and final chapter, the casting process.
The first step in the casting process is to create an exact model of the piece by creating a rubber mold; which is done by covering the original sculpture with a layer of wax or silicone. When the rubber hardens a mother mold is made to support the rubber to receive a special wax. The special type of molten wax is poured into the mold in layers; the wax is removed from the mold and detailed to make it exactly like the original. Before actual casting, there are sprues or gates attached with pouring cups to the wax cast. Next, the ceramic mold is built by dipping the wax casting into an investment liquid a number of times building up the structure of the mold. Between each drip, it is allowed to dry. The ceramic shell is then fired and the wax melts out of the shell creating a hollow shell. Hence the lost wax method.
Liquid bronze is poured into the ceramic shell. After cooling the ceramic shell is broken away leaving the bronze piece. The piece is then chased, re-detailed, welded together if necessary, and polished ready for the patina process.
Using an artisans torch the bronze is heated and chemicals are applied to create various patinas. Wax is applied to attain the proper luster. A base of marble or granite that have varying dimensions to suit the sculpture is used and the bronze is bolted to the base.