The original form is sculpted out of a wax-based clay called plasticene over an aluminum wire armature.
The sculpture is cut into smaller pieces before being covered with liquid Silicone rubber to make a two part mold. The rubber mold is backed up by a supporting ("mother") mold made of plaster to keep the rubber stiff and in its intended position.
This mold is used to pour liquid wax into and make a copy of the original sculpture. Larger parts of the sculpture are poured hollow by draining out the center of the wax before it has had a chance to solidify. The wax copy of the original sculpture is mounted to a system of wax vents, called a sprew sytstem, and a wax "pouring cup."
This system is dipped into a ceramic slurry bath and then sprinkled with silica sand. This makes the first coat of a ceramic shell mold over the wax. After it dries, other coats are added to give the shell a thickness that is strong enough to hold liquid bronze.
When completely dry, the shell is placed in a furnace and "burned out." The wax melts away and the ceramic vitrifies like pottery.
The ceramic shell molds are braced in a casting pit while the molten bronze is removed from a crucible furnace. The bronze is poured into the vitrified ceramic mold at about 2000°F.
The mold is removed from the bronze many hours later with an air hammer and sand blaster. The sprew system that is now bronze is cut off and the sculpture parts are now welded together. The surface of the complete sculpture is then finished with die grinders and chisels, making sure to eliminate seams and mold particulars that may not have been fully removed with sand blasting.
The finished bronze is patined with various chemicals, such as copper (which oxidizes to blue-green), bismuth, and cobalt. The patina is sealed with wax to halt future oxidization and buffed to a shine.
The sculpture is then mounted to a patented black granite base and placed on a pedestal or piece of furniture for your enjoyment!