Author: Olivier Duhamel
ISBN: ISBN-10: 145158475X ISBN-13: 978-1451584752
Page count: 114
Genre: non fiction
Price: USD 29.95 (Paperback) or USD 16 (PDF)
Author Bio:
Olivier Duhamel is a sculptor established in New Zealand. He specializes in small figurative bronze sculptures which he sells through art galleries in New Zealand, in Australia, in France, in Belgium and in China.
Tell us about your book:
Written for professional sculptors and hobbyists, the “Bronze Casting Manual” is a tutorial teaching the lost wax and ceramic shell techniques.
It is a complete tutorial taking the reader step by step through an easily achievable casting project.
The manual will introduce the reader to the basics of wax working, sprueing a wax model, mixing and applying a ceramic slurry, making a crucible and constructing an efficient yet affordable furnace, melting and pouring the metal and finally chasing, fettling the bronze before applying a simple patina.
More advanced casting techniques are discussed in a second part that also gives further advice on how to set up a small, home based art foundry.
The manual includes an extensive list of suppliers around the world, making it easy to source the necessary tools and materials.
How long did it take to write the book?
6 months
What inspired you to write the book?
By casting my own bronze sculpture I saved myself much money. Over the years I have perfected the craft to a fine art and thought that many other artists, craftsmen and hobbyists could benefit from using the same techniques. There is nothing new in the techniques I use, but I have adapted industry standard methods so that the process becomes accessible and affordable for the hobbyist and the occasional metal smith.
By using a detailed step by step format, I am aiming at taking the guess work out of bronze casting, allowing the reader to successfully create a small bronze object at the first attempt.
Talk about the writing process. Did you have a writing routine? Did you do any research, and if so, what did that involve?
The book basically follows a simple casting project from A to Z. I simply photographed and documented every steps of the project as I went along, taking note of every single detail, measuring every quantity used and then transcribing it all in a word processor at the end of each day. The bulk of the book was all finished within one week. With this writing method I have been able to produce something simple and easy to follow but completely thorough as every single aspect is documented.
I asked a few friends to test rive the manual and actually follow my directions to see if they could actually produce a bronze object. They could, I incorporated their feedback.
For the second part of the manual, I discuss some more advanced techniques that were not implemented in the simple project. I asked a number of fellow sculptors to validate my directions.
The rest was to do with formatting and proof reading, getting and incorporating feedback before actually publishing.
What do you hope your readers come away with after reading your book?
My sincerest hope is that many people will actually melt metal and cast a small bronze object by themselves. I wish that this book will allow many people to safely and easily experience the magic and the excitement of melting metal to create a noble, durable and beautiful bronze object
This is not limited to artists, art students and sculptors. The techniques described can also be used to make medallions, plaques, signs, door knockers, hubcaps, doorknobs, bookends, urns, belt buckles, bells, crucifixes, crosses, Buddha’s, boat parts and chandlery, antique bathtub legs and claw legs sheaths, pommels, knife hilts and handles, baby hands and feet and more.
Where can we go to buy your book?
The book can be bought as a PDF file from my website on www.bodyscape.net.nz
It can also be found as a paperback (10 x 8 x 0.3 inches ) on amazon.com at http://www.amazon.com/Bronze-Casting-Manual-achievable-professional/dp/145158475X/ref=sr_1_9?ie=UTF8&s=books&qid=1273528757&sr=1-9
Any other links or info you’d like to share?
The author can be contacted on olivier.duhamel@bodyscape.net.nz
Excerpt from book:
Table of contents.
Introduction 7
About bronze casting 8
Tools, materials and equipment 9
Project overview 10
Process overview 11
Before starting 15
Making a wax sculpture 16
Sprueing. 23
Making a wax crucible 36
Constructing the ceramic shell. 40
Dewaxing 47
Reinforcing the shell 50
Constructing the furnace 52
Baking, melting and pouring 55
Chasing and fettling 67
Patina. 71
Taking it further 75
Casting more than one piece at a time 76
Casting larger pieces 77
Making a steel handle for large shells 78
Hollow casting principles 79
Making a hollow wax 84
Casting an edition 86
Advanced feeding system design 87
Appendix A – Index of tools and materials 91
Appendix B – Check list 97
Appendix C – Art foundries 98
Appendix D – Foundry supply 104
Appendix E – Workshops and Courses 110
Appendix F – Other resources 112
About the author 113
Project overview
The tutorial takes you through all the steps necessary to make a small, fist size bronze sculpture, from making the original sculpture to finishing the final bronze reproduction.
This practical project will not show you more advanced casting techniques such as hollow casting and will not explain how to make multiple reproductions of the same original. These topics will be treated in later chapters of the manual and can be discussed in our forum on: www.bodyscape.net.nz/forum.htm
The tutorial will not have you establishing a complete backyard foundry. The furnace is a temporary, fold away furnace and most tools and equipment can be found in DIY enthusiast’s workshops or garden sheds.
You will be introduced to many new terms that you may find confusing. The following section “Process overview” has some illustrations that will introduce you to such concepts and make things much clearer before you proceed further.
The project can take as little as 5 or 6 days to complete and will consist of the following steps.
First day – Sculpting
You will first be making a small sculpture in wax. It is essential that it is made in wax. Please do not start making a masterpiece in clay or other molding material.
The manual will use two different example sculptures:
1 A small female torso about 10cm tall (4 in)
2 A small round medallion about 10 cm in diameter (4 in)
Second day – “Sprueing”
The wax figurine will then be prepared for the mold. You will continue to learn the basics of wax working.
Second and Third day – “Shelling-up”
The wax will then be encased in a ceramic mold, called “shell”, which is painted in its liquid form in several layers over the wax and then left to dry
Fourth day - “De-waxing”
Once the shell is dry, you will use a gas torch to melt the wax out of the shell. This is called “de-waxing” or “burning out”. You will then have an empty negative of your original shape, a ceramic mold.
Fourth day – Melting and Pouring
A simple temporary furnace needs to be built and metal melted inside a crucible before it is poured in the empty shell. This is the most exciting part of the process. Do not be intimidated, the method is both safe and easy.
Fifth day – “Knocking-off” and “Chasing”
Once the metal has cooled and solidified, the shell can be knocked off to free the newborn bronze sculpture. It will then need to be cleaned and any imperfections smoothed out. This process is called “chasing”.
Sixth day – Patina
Finally, the new sculpture will be given a surface finish. This is known as patina. Bronze will naturally oxidize and acquire deep and rich colors known as “Patina”. This is a very slow process that can be considerably accelerated. The manual demonstrates the most common patina techniques.
There will be some other intermediary steps, such as making a crucible. You could buy a crucible, but in an effort to keep cost to a minimum we will explain how to make your own.
The entire project can be completed by one person working alone. However, we would recommend that for safety reasons you have a second person present when you are melting the metal.







