Lost-wax casting is a technique that has been used for centuries to produce highly detailed metal works. Today, 3D printing makes it possible to modernize this traditional process by accelerating model production while preserving an exceptional level of detail.
At Axis Prototypes, we recently contributed to the creation of a bronze statue of the Virgin Mary holding the Child Jesus, intended to be installed on a funeral monument at the Notre-Dame-des-Neiges Cemetery in Montreal.
This project perfectly illustrates how 3D scanning, rapid prototyping, and SLA additive manufacturing can be integrated with traditional foundry processes to create durable, high-quality works of art.
The project began with the 3D scanning of an existing wooden statue. This step allowed us to accurately capture all the details of the original artwork and create a precise digital model.
Using the collected data, our team developed a 3D file optimized for the foundry process, including a uniform wall thickness of 3/8 inch to meet the technical requirements of the project.
This approach makes it possible to preserve the artistic details of the original work while preparing the model for the subsequent manufacturing stages.
Once the digital model was finalized, it was produced using our SLA 3D printing technology with the Tetrashell process.
This technology is particularly well suited to lost-wax casting, as it makes it possible to produce lightweight, precise parts designed to burn out efficiently during the mold firing process.
3D printing also provides significant design freedom and makes it possible to reproduce complex details that would be difficult to achieve using conventional manufacturing methods.
The printed model was then sent to a foundry specializing in bronze casting.
Using the 3D-printed part, a ceramic mold was created around the model. Once the mold had fully hardened, it was heated to burn out the printed model inside.
This step is at the heart of the lost-wax casting process, as it creates a cavity that accurately reproduces the geometry of the original sculpture.
Once the cavity was created, it was filled with molten bronze.
After the metal had cooled, the ceramic mold was carefully broken away to reveal the bronze part. This technique makes it possible to produce complex sculptures with an exceptional level of detail.
After the bronze parts were removed from the mold, several finishing steps were required to achieve the final result.
The feeding channels used during the casting process were removed, and the different sections of the statue were welded together. Careful grinding and sanding were then performed to create a uniform surface and a high-quality finish.
A patina was finally applied to the bronze to give the statue its final appearance and help protect the metal from the elements.
Once completed, the statue of the Virgin Mary and the Child Jesus was assembled on its funeral monument and installed at the Notre-Dame-des-Neiges Cemetery in Montreal.
This project demonstrates how combining traditional foundry techniques with modern technologies such as 3D scanning, rapid prototyping, and SLA 3D printing makes it possible to produce complex works with remarkable precision.
Lost-wax casting assisted by 3D printing opens up new possibilities for artists, sculptors, foundries, and heritage professionals. Thanks to 3D scanning and additive manufacturing, it is now possible to accurately reproduce existing works, reduce manufacturing lead times, and optimize production processes.
At Axis Prototypes, we are proud to put our technologies to work on unique projects where innovation meets art, heritage, and traditional craftsmanship.
