Sculptor Andrew DeVries removes an arm from the clay model in preparation for the rubber mold
Shims form a dividing line - these are carefully inserted into the clay model
Shims inserted into a large clay model to divide the sculpture into sections
The first coat of rubber, in this case a polyurethane rubber, is painted on
More coats of rubber are painted on - these coats have been thickened with fumed silica to form a mayonnaise viscosity
A plaster back up mold is put over the rubber, often reinforced with hemp and rod to strengthen the plaster, this holds the rubber to its shape
The rubber is opened and the original clay is removed, the first coat of wax is painted in to capture the surface detail
The rubber mold is strapped tightly together and hot wax is poured in
The wax is poured out and this step is repeated one or two more times letting each coat cool before pouring in again
The plaster mother mold is removed and the rubber is carefully pulled off after the wax has thoroughly cooled
The wax casting should be an even 1/8 inch to 3/16 inch thick
The wax casting is "chased", mold lines are removed and any air entrapment is filled with wax and also finished, this is extremely important
Red wax gates and vents are attached to the wax casting, gates will act as channels to feed bronze into the casting, vents take air out of the casting
This shows how the casting will actually be poured, the feeding gate is behind, the red vents take air back to the top of the pour cup
The first coat of slurry is poured over and inside the wax casting, gates and vents, this will create the inner core and outer ceramic shell mold
Slurry is a mixture of colloidal silica and silica and/or zircon flour
A fine coat of zircon sand is sifted onto the slurry coated wax casting
Additional coats of slurry will be applied by dipping the wax casting into a large tank of slurry with more stucco coats added after each dip, the slurry will be allowed to drip off before coating with stucco
Each coat must thoroughly dry before the next, tubes of forced air are put inside to dry the inner core
After many coats the wax is melted out thus the term "lost wax' the ceramic shell mold is removed from the dewax oven and inspected for any defects
The ceramic shell molds are preheated in an oven before casting metal into them
The bronze is melted in a crucible inside the furnace, when ready is removed and the metal is cast into the ceramic shell mold which has been packed in sand
The ceramic shell mold is removed after the casting has cooled
The bronze is then sandblasted clean removing all shell from the surface
The feeding gates are cut off and rough ground off
Hand filing is done to "chase" the bronze -returning the casting to its original shape
Sections are welded back together, these welds too must be chased
Hand filing refines the details
A final inspection for any metal flaws, these will be welded, filled with bronze and chased
The final step is the patina, the bronze is heated and chemicals are applied which change the color to the artist's vision
A master sculptor and founder of the lost wax method, Andrew unlike most sculptors today, casts and finishes his own works at River Studio, high in the Berkshire foothills.
Bronze is an alloy and has been the medium chosen by many of the greatest sculptors from the early Greek civilization through the Renaissance to modern masters. It calls to mind the names of masterpieces such as Ghiberti's baptistry doors in Florence, the Gates of Hell by Rodin in Paris, as well as modern abstract works by Brancusi, Giacometti and Henry Moore. Held in reverence by collectors and art lovers, bronzes are soaring in value at sales and auctions.
What gives a sculpture value?
Originality, superb craftsmanship with low numbered editions - all found in Andrew's works, where he imbues his unique esthetic, developed over four decades, into every aspect of each individual sculpture. You can grasp the quality that he brings into every aspect to his work.
In the artist's own words...
"Our passion is the best way to show gratitude for life - that is what I do in my art"
