The Lost Wax Process

Once a piece is ready to leave the studio, it is transformed into a limited edition bronze of the finest quality, by the centuries-old lost-wax process:

Ken's works are sent to the specialized bronze art foundry in Prescott, Arizona. The painstaking process by which a high-tolerance cast is made will reproduce even the finest details.

1. A silicon rubber master mould is made of the original sculpture, producing an exact copy of the original.

2. Molten wax is then poured into the mould to form a series of hollow wax casts, each having a separate number with date and Ken's signature.

3. The wax replica is then carefully fettled and set up for casting, this critical step involves the expert placing of runners and risers - tubes around the shape which allow air, then wax, to escape from the mould as the metal is poured.

4. The piece is then subjected to successive dips in fine ceramic slurry which is dried between dips, building up a hard mould around the wax.

5. The ceramic mould is heated in a kiln, which results in the wax melting out, leaving a clean, empty cavity inside the ceramic mould.

6. Fine silicon bronze is melted in a super heated furnace, and then poured into the heated mould, filling the cavity.

7. Once cooled the ceramic shell is chipped away and the runners and risers removed. The bronze is thoroughly cleaned to remove all traces of the ceramic shell.

8. Once the piece has been completely cleaned, the surface is burnished to a fine finish. The artist inspects the bronze sculpture to ensure that it is an accurate replica of the original clay.

9. The final step adds a patina to the sculpture; the piece is then polished with beeswax and the limited edition sculpture is complete

Ken meticulously monitors every detail during his final inspection.


Care and maintenance: No further maintenance is necessary apart from dusting and the occasional polish with beeswax or commercial furniture wax.