The lost wax method used by Egan Bronze classic Mediterranean oil lamps cast in bronze with patina, title image

Wax burn-out oven (background)

This method begins by creating an original sculpture in wax, clay, marble or any other suitable material.

In modern methods, we make a rubber mold of the original masterpiece in order to reproduce the original. We then remove the original piece from the rubber. With our rubber now hollow we are able to pour into the rubber, a measured amount of wax. The wax will chill and can be taken out of the rubber mold and any corrections or parting lines can be cleaned up. These hollow wax “lamps” are then attached to one another by wax bars called sprues, runners, gates and vents. A plaster, high temperature sand and fiberglass mixture is then prepared in sufficient quantity to cover this wax “tree” to a thickness several inches around. After the plaster has set, it is baked in an oven for 16 hours at an ascending temperature to 1400 degrees. It is at this time that the wax is lost (melted/vaporized) from the plaster. In a separate furnace we are melting bronze to a temperature of 2000 degrees. Once that temperature is reached we pull the molds from the oven and pour the metal in. When cool, the molds are broken open, plaster removed, sprues cut off, metal chaised and patinated.

Frank Egan 1999 - 2017