Excalibur Bronze

309 Starr Street, Brooklyn, NY 11237
(718) 366-3444

Casting

The ceramic dipped wax is next burned out. It is placed upside down into a specially designed oven at very high temperature until the wax melts out of the ceramic shell and any residue is completely burned out. The temperature is then increased in the oven and the cermaic is baked in order to calcify and harden it. During the tail end of the burn out process, the metal furnace is started and the melting of the metal begun.

Once the ceramic shells are completely burned out and calcified and the molten metal are at an appropriate temperature (usually in the range of 1800-2100 degrees farenheit for silicon bronze, depending upon the piece to be poured), the ceramic shells are removed from the oven and stacked in a sand box or pit. The crucible of molten metal is then removed from the furnace and rigged to a pulley mechanism which is used to position it above the cermaic shells. The metal is then poured into the ceramic shells and allowed to cool. Once the castings are fully cooled, the ceramic shell is broken off. A pour in process can be seen below.

Casting