EXTENDED PLAY
Look at how our artists solve the problem of rendering foam core and masking tape and cast it in bronze
THE PROCESS
I love that I get to wake up every day and make art for a living.
–Vanessa
Wax Artisan
| As the foundation of the casting process, the creation of a mold requires great care, expertise, and fastidious attention to detail. Whether for metal castings, architectural elements, or other sculptural applications; each mold faithfully preserves the original’s qualities. Our rigorous process ensures the mold is efficiently designed for quality castings and a long life. |  |
We use Westech’s pattern wax (ISO 9000:2015 certified) that captures the mold with absolute precision and over 35 years of experience and innovation. Keeping the thickness at ¼ inch, our experienced wax artisans can smoothly roll the molds to get an even and undisturbed surface consistently for any edition size. Our unique gating system allows optimal metal flow through the shell cavity causing our castings to have a decrease in any metal imperfections. |  |
Creating the ceramic shell requires dipping the wax in slurry multiple times to build up in thickness and strength. Using a Techsol binder with 3M’s Rapid Cast flour and Accelerator, our shells can be dipped with fewer coats; increasing productivity while still maintaining its strength and quality. We use a fine “A” and “B” sand to perfectly capture the intricacies of the pattern so that every detail down to a thumbprint will be transferred to metal. |  |
We also use resin bonded sand-casting which is a “waste mold system”. This just means that the mold is broken with each casting since the high heat of the metal destroys the surface of the mold. The binder fuses the sand grains together well enough to allow metal to be poured into the mold and have the mold cavity hold its shape until the metal solidifies. Sand castings require a pattern on which the sand mixed with binder is rammed and carefully removed once set. The pattern must, therefore, be draft-able without undercuts which would prevent the mold from being pulled from the pattern. We typically recommend this method for larger relatively flat pieces. This saves on client costs and artisan time. |  |
Unlike most other foundries, we are able to pour large shells (some ranging up to 33”x46”) which allows for less reworking and metal chasing, keeping the integrity of your original accurately. Along with shell casting we use the sandcasting method for larger, drafted panels or reliefs. We use silicon bronze ingots that are shot blasted to be free of surface impurities for a clean pour with great fluidity. |  |
| Upon the cooling of the cast bronze ceramic shell, the shell is “devested” from the now solid bronze casting. Following removal of the ceramic shell, the gating system is cut off from the cast sculpture scection. The rough casting is then media blasted to remove any remaining ceramic shell. |  |
casting
We use a combination of an evolved shell/lost wax process and an environmentally friendly sand casting system for our projects. We’ve developed our own techniques for the intelligence and efficiency of each process, and we are always innovating.
Metals and other casting materials we use include
The possibilities here are immense, and we have a track record of innovative projects across different industries. This is also an area where we show range in our project management. We fabricate in Stainless Steel, Aluminum and Bronze.
fabrication
You never know what kind of sculptures you'll be working on or what techniques you'll have to pull out.
–James
Metal Chaser
finishing
I take pride in the fact that my hands are the last to touch the artwork.
– Matt
Patina Artisan
The final stages of a project are critical. The finish is always a product of how well all the previous processes are done, and we strive to nail the artist’s vision in this final stage. We offer a library of patinas and surface treatments to our artists, and many of these become personalized to the artist’s vision.
Finishing capabilities include
PATINA
BOLLINGER specializes in the restoration, repair and on-going care of sculpture and architectural elements.
The company’s team of highly trained artisans apply their skills to a broad range of services, restoring the value and beauty of sculptural objects for individuals, major cities, museums and exquisite private collections.
Established in 1977 and led by sculptor Tom Bollinger, Arizona Bronze Sculpture Restoration maintains the highest industry standards and offers rare skills in restoration and metal work.
Services include repair, patination, waxing as well as ongoing maintenance and relocation of sculpture.
Our artisans work at your location or in our studio depending on the work requirements.
For bronze casting and sculpture fabrication services, please contact our renown affiliate company, Bollinger Atelier, serving artists worldwide.
patina finish samples
I love challenges. We're never doing the same thing.
–Mike
Fabrication Supervisor
When we produce artworks at Bollinger Atelier, we design them to withstand the elements. As a preventative measure, we provide our clients with care instructions for each work we produce. Over time, however, all works require maintenance to mitigate the effects of time and environment, whether natural or accidental.
When works require it, we offer comprehensive restoration services, including refinishing, repairs, and technical support. Please contact ARIZONA BRONZE for quotes on new projects.
Restoration Examples
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pre-production
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finalization