The Foundry
True to the metal history of the Magic City for which it is named, Birmingham Sculpture is a full service foundry that transforms molten material into tools, sculpture, fixtures, and timeless treasures.
Once the wax sculptures arrive to the foundry, the designs are attached with sprues and gates to allow for the flow of air, wax, and brass.
Next, each piece goes through the lengthy process of 8 dippings in ceramic shell, a combination of silicate powder and slurry.
Once thoroughly layered and dried, the pieces are heated in the burn out kiln. Simultaneously the wax is melted out and the ceramic shell hardens into a durable, egg-like shell. The forms are now ready for the pour.
In prepping for the pour, brass ingots are added to a designated brass crucible which is brought up to 1750 degrees Fahrenheit.
Protected from head to toe in heat proof gear, the foundry team works in tandem to methodically pour the molten brass into each shell.
The forms, aesthetic marvels in their own right, are set to cool and harden for hours.
The next step has an archeological excavation vibe as anticipation builds and the design is carefully broken and chiseled to expose the form within.
Lastly, the design is sandblasted and, once again, meticulously chased with a variety of tools to match the artist’s proof originally designed in wax.
