The journey of transforming a small-scale sculpture, or maquette, into a finished bronze piece begins with precision and technology. At Bollinger Atelier, we use advanced 3D scanning and digital sculpting techniques to enlarge and refine artworks. This ensures every detail is preserved in the transition from concept to final cast. Think of 3D scanning like taking hundreds of high-resolution photos from different angles and stitching them together to create a perfect digital twin of the sculpture. This article focuses on the crucial initial stages that set the foundation for a successful bronze casting.

The process starts with an in-depth consultation with the artist. Understanding the artistic vision is key, along with discussing the final scale and identifying potential challenges. Some details in the maquette may need refinement before scanning, such as delicate textures or undercuts that may not translate well at a larger scale. Addressing these considerations early ensures a smoother transition to the final sculpture.

From Maquette to Monument: 3D Scanning to Capture the Detail

Once the maquette is ready, high-resolution 3D scanning captures every nuance. As the scanner sweeps over the sculpture, thousands of tiny data points are collected, mapping every contour and texture with astonishing precision. Multiple scans from different angles are merged to create a clean, watertight digital model. This process ensures that even the finest details—like fingerprint impressions in clay or subtle chisel marks—are preserved for the next stages of enlargement.

After 3D scanning, the digital model undergoes processing and scaling. This includes cleaning up imperfections, filling in missing areas, and ensuring structural soundness for casting. Adjustments refine proportions, modify wall thickness, and reinforce delicate areas. Digital sculpting tools enhance features and textures to ensure the sculpture maintains its intended look at a larger scale. Before digital scanning, sculptors had to painstakingly recreate their work at full scale by hand, often losing some of the spontaneity of the original. Now, digital tools preserve the nuance, making the process more precise and efficient.

Larger Than Life Scale: Milling the Digital Model

For sculptures exceeding the milling machine’s capacity, the model is digitally sectioned. Careful planning ensures all pieces fit seamlessly once machined. Registration marks or dowel holes maintain alignment, while toolpath preparation optimizes material use and machining efficiency.

CNC foam milling brings the digital model to life in a tangible form. We use high-density polyurethane or EPS foam to carve out the enlarged sections with precision, minimizing the need for hand-sculpting. Our artisans then make any small refinements as needed, to make sure the enlargement stays true to the artist’s vision. This faithful representation of the original maquette sets the stage for the next casting phases.

At our Atelier, these steps bridge traditional artistry with modern technology, seamlessly transitioning from small-scale model to large-scale sculpture. The digital processes of 3D scanning and CNC milling represent the future of the foundry. We allow artists to push boundaries with accuracy and efficiency. By using digital tools with traditional lost wax casting techniques, we honor the craftsmanship of the past while embracing the possibilities of the future. This fusion of time-honored techniques and cutting-edge technology ensures every bronze sculpture is both a tribute to tradition and a step forward in sculptural innovation.