Step 1:


A mold is made from the prototype in order to produce the wax copy.

Materials: Rubber (cold, warm, or pressed, depending on the prototype material) and plaster or fiberglass. Aluminum tools can be created for cases of mass production.

Step 2:


Creation of the wax copy from the mold either handmade for unique pieces and small editions or mechanically by using our wax injection machine for mass production.

Step 3:


Retouching the wax copy and correcting any imperfections.   Our foundry has a resident sculptor on hand to supervise this stage.

Step 4:


Gates need to be attached to the wax copy, functioning as canals. These canals allow the metal to fill up the piece evenly.

Step 5:


The ceramic shell is then applied to the piece in layers. Ceramic shell technology was developed in America to provide perfect castings for aerospace applications. We are the only foundry in Greece and one of the first foundries in Europe to use this technique.

Step 6:


The piece is then placed in the de-wax kiln where the wax melts out leaving behind a hollow negative into which the melted metal will be poured. This is the lost wax method.

Step 7:


At this point we are ready to pour the melted metal. Even the same alloys need to be poured at different temperatures and different rates, to obtain the optimum quality possible. We have honed our techniques for this stage with over 30 years of experience, allowing us to overcome any problems as and when they arise.

Step 8:


Once the metal has cooled the ceramic shell and the gates are removed. Our team of metal workers then brings the piece to its final finished state.

Step 9:


The final step is to apply the patina. Patination relies on different acids and their reactions with particular metals. We offer a huge range of coloration and visual textures.

 

Specialized patinas

 

More photos

The above photographs are from the work of sculptor Aggelos Vlassis


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