Blog - Martin Pierce

limited edition artwork

A simple and complicated mold for lost wax casting

  A simple and complicated mold for lost wax casting

 Martin’s art journey continues and the story line of the insect world of giant insects is evolving as he begins to depict the dung beetle’s family life.

In nature many dung beetles have been photographed  moving their prized dung balls with alacritous backward leg movement. The dung ball is prized as it can be used as a food source or as a site for the female dung beetle to lay her eggs in which is called a brood ball.

In Martin’s fictional world he has opted to create a more faceted airy dung ball and one with organic hollows that will eventually be populated with offspring or dung beetle artifacts.

The patterns has been created, 3 molds have been made and the first red wax replicas have been poured.

The dung ball pattern began with a turned round wooden ball. A hollow fiberglass shell was molded over the ball by applying successive layers of fiberglass cloth sandwiched together with resin. Once set, the fiberglass ball was cut and removed from the wooden ball leaving a hollow shell. An organic design was drawn onto the face of the shell, and using a Dremel, sections were cut out and removed. The fiberglass shell was coated with three layers of gesso which was sanded to soften the edges. The shell was sprayed with primer and work on the mold began.

While the mold was made using simple compounds the process was complicated and time consuming. Layers of liquid rubber were built up inside the perforated shell. To prevent the rubber from pouring through, the holes of the shell were filled in with pieces of modelling clay molded by hand to fit each irregular hole. The outside of the shell was then coated with coats of liquid rubber and once set the rubberized outer shell was hardened with successive applications of fiberglass cloth and resin. Prior to the mold being made the pattern was treated with a release agent to prevent the mold material from forming a permanent bond. The end result is a 2-part hollow mold that is now used to make red wax replicas of the original pattern.

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Custom door hardware - an index of posts on the process

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Over the years of writing my blog I have often described the process from designing to casting door hardware using the lost wax method but have not until now felt it necessary to index  these posts.

The posts are broken down into 5 areas that describe the process from inception to end product. If you have limited reading time there is one piece that covers most of the stages that was was posted on June 21st 2017.

For details on the different stages please read on.

STAGE 1 - Design

These posts follow the creative process from the initial sketch to more detailed drawings that show the piece from different perspectives. They explain how the technical aspects of lost wax casting as well as the functional requirements of door hardware impact the design and result in modifications to the original concept.

https://www.martinpierce.com/blog/dragon-and-netsuke-door-knobs

https://www.martinpierce.com/blog/custom-designed-door-hardware-some-common-misunderstandings

https://www.martinpierce.com/blog/early-designs-for-a-new-entry-door-pull

https://www.martinpierce.com/blog/candlesticks-new-designs

https://www.martinpierce.com/blog/new-morphic-door-pull-one-size-does-not-fit-all

Stage 1 - detailed drawing from 2 perspectives Stage 2 - rough carving of pattern later refined

STAGE 2 – Pattern making

Lost wax casting requires an  original pattern or sculpture to be created. We create our patterns by sculpting  in a hard wood, blue wax or high-density foam. Our method is reductive and rarely makes use of 3D printing and we explain why in these posts.

https://www.martinpierce.com/blog/bumble-bee-cabinet-knob

https://www.martinpierce.com/blog/dog-door-knobs

https://www.martinpierce.com/blog/new-carp-fish-door-pull

https://www.martinpierce.com/blog/why-research-and-development-costs-for-custom-hardware-is-expensive-part-2

https://www.martinpierce.com/blog/3d-printing-as-useful-tool-in-casting-custom-door-handles

STAGE 3 - Mold making, gates and sprues

A mold of the pattern is made. The number of molds needed for one design depends on the complexity of the design and in assessing how the molten bronze will flow. The pattern is fitted with one central sprue and several gates that attach to the sprue and the edge of the pattern. A mold (s) is then  made of the pattern with the sprue and gates attached.

https://www.martinpierce.com/blog/how-to-make-a-simple-mold-for-lost-wax-casting

https://www.martinpierce.com/blog/how-to-cast-bronze-butteflies-good-and-bad-runners-and-gates

STAGE 4 – Wax replicas and shelling

The lost wax method requires a wax replica to be made for all the component parts needed to make one piece. The Hedgerow door lever for example require 4 waxes to be made; one for the escutcheon, one for the lever, 2 for the tree canopy. The waxes are then dipped in a silicone slurry that when hardened forms a shell that encases the wax. An auto-clave is used to remove the wax (lost wax)  and the hollow shell is ready to receive molten metal.

https://www.martinpierce.com/blog/wine-cellar-door-handles-and-shell-casting

https://www.martinpierce.com/blog/using-wax-facsimiles-to-create-bronze-door-handles

 https://www.martinpierce.com/blog/hawaiian-theme-door-handle

https://www.martinpierce.com/blog/creating-a-custom-appliance-pull-using-the-lost-wax-process-the-wax-stage

 https://www.martinpierce.com/blog/limited-edition-door-handles

Wax replicas ready to be shelled

 

Which art form do you prefer--original or reproduction?

Limited edition Ascot sideboard with vine japanning detail from Martin Pierce Custom Hardware We certainly view our custom designed architectural hardware and furniture pieces as artwork and often refer to them as functional art.  But, fortunately for all of us,  art comes in many affordable forms.  Lisa Leonard from LML Art Group in San Diego, California shared some of her expertise to help you make the right choice for your project.

Original:  Original art is just what it says--a piece of art that is in it's original format. This would include a painting, drawing, sculpture, weaving, etc.   While prints or limited editions may be created from this item,  the original is always the first one produced.  In the event that no reproductions are made then the original becomes an often valuable one-of-a-kind item.

Limited Edition:  When an artist creates a specific number of the same piece and then destroys the mold, for example, it becomes a limited edition piece.  Each piece is numbered so that you are aware of the order in which your piece was cast or created. There are differing schools of thought on the value of the number.  With our obsession with the #1 in this society, some collectors feel that the lower the number the more valuable the piece.  Conversely, others believe that the final number in an edition is more valuable as it is the last one created.  For your enjoyment, Ms. Leonard recommends that, if you have a choice you select a number that is important to you such as an anniversary or birthdate or your own "lucky" number.  At Martin Pierce, we offer limited editions in some of our furniture and hardware collections and those can be viewed by visiting our site.

Print: Prints or off set lithographs are the most inexpensive form of reproduction. They are photo mechanically produced, usually on thin paper.  A good way to make sure you are receiving the form you are paying for, take a look at the item under a magnifying glass.... a print will show a series of dots that make up the image while the more expensive silkscreen will show a solid wash of color.

Silkscreens:  While silkscreens are also printed, it is onto heavier paper and with a time intensive process of paint screened onto paper with each color requiring a different screen until the image is complete.  Silkscreens are often offered in a limited edition, thereby increasing the cost and perhaps even the value.

Giclees:  Giclees are computer generated with ink jet printers similar to your own home printer.  However, the paper is much heavier and the ink (paint) is denser.  Giclees were originally printed as limited editions and considered quite valuable.   While they are more expensive than an off-set print, today's technology makes it possible to print them in vast quantities and they are not considered a from of original art.

The beauty and value of any piece of art lies in the eyes of the beholder but it is also good to be armed with some knowledge before making these very important purchases.

To view our entire collection of custom and/or limited edition hardware and furniture, please visit our site at www.martinpierce.com.

What is a limited edition item?

We often talk about limited edition collections on this blog.  For example, we have recently mentioned our Aspen Buffet, limited edition of 30.  But many people ask us "what exactly is a limited edition?" Simply put, a limited edition is just that, a limited number of a particular item is produced and released for sale or, as wikipedia defines it "a restricted number of copies are produced."  There is no limit to the number in any limited edition but it makes sense that the smaller the number to the release the more valuable the item may be.  Contrary to popular belief, no specific number in a limited edition is any more valuable than another.  Some collectors always want the first of any release while others view the last number more collectible.  Many people choose a number that is significant to their lives such as an anniversary date, birthdate of a child or even their football jersey number....there is no limit to one's imagination!

In the example of our Aspen Buffet, a limited edition really means one of a kind as no two pieces will be exactly alike. This is due to the fact that the furniture is entirely hand-made and hand-assembled in our shop,, making this furniture a functional piece of art.  What is copied or reproduced is the design of the buffet as well as the decorative inlaid design and japanning technique used to create that design.

martin pierce aspen buffet

Hope this clears up any questions about purchasing a limited edition of any type of artwork, furniture, books or these days, even video games and electronics.  And,  as always, you can view our entire collection or contact us for bespoke orders at www.martinpierce.com.