Collectors often ask me how a clay sculpture makes its way to bronze. It’s a process filled with craftsmanship, patience, and transformation. In this video, I take you inside my studio to show the very first stage of that journey—how I turn my original clay sculpture into wax castings ready for the foundry.
Once I’m completely happy with my clay sculpture, I coat it in a few layers of shellac. This hardens the surface and locks in every detail I’ve spent weeks refining. Then, I construct clay walls that define the mold seams. These are made from the same clay as the sculpture itself, softened in the oven to keep it pliable and help it adhere cleanly.
Each wall is carefully smoothed and cut with “keys”—small notches that ensure the mold halves align perfectly when reassembled. A release agent is sprayed on to prevent sticking, and from there I apply several layers of urethane rubber to capture every nuance of the original clay.
To give the flexible rubber jacket strength, I build a “mother mold.” Made from an epoxy paste, this rigid outer shell keeps everything stable during casting. For larger or more complex forms, I add hardwood legs—these serve both as handles and supports when the mold is flipped upside down for pouring.
Next comes one of my favorite parts: pouring the hot wax. Heated to about 250°F, the molten wax is poured into the mold and rolled around by hand, layer by layer. After several coats, the wax cools and hardens into a hollow replica of the original sculpture.
At this point, I remove the wax from the mold and begin “chasing.” This is where I clean up seams, repair surface blemishes, and restore the subtle details of the original clay. Every mark matters—because whatever is in the wax will be exactly reproduced in bronze.
Once the waxes are complete, they’re ready to move on to the foundry. There, the wax will be used to create ceramic molds and eventually replaced by molten bronze. But for now, my work in the studio is done—the sculpture has made its first major transformation, from soft clay to solid wax.
In a future video, I’ll share what happens when the bronze returns from the foundry—how I chase the metal, refine the surfaces, and apply the patina that brings each sculpture to life. For now, I hope you enjoy this inside look at the earliest and perhaps most intricate stage of the bronze-making process.
Fresh Updates from the Studio
