The Lost Wax Process

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The Lost Wax Process
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The Lost Wax Process
At our host foundry in Hiram, Maine we continue
the age-old tradition of lost wax casting,
combined with the work ethic and skills that
Maine craftsmen are famous for. We have, however,
added some modern tools to help in the process.
While wax patterns are still used, today we
utilize a laser cutter to create the intricate
designs. Modern synthetic rubbers have been
developed which capture the very fine detail and
can flex to release undercut areas of the model,
greatly reducing the number of mold parts and the
number of parting lines, when compared to the
earlier techniques of using wet plaster molds.
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The Lost Wax Process
At this point in the process, the pattern looks
exactly like the finished metal bell will look
except it is in wax. The pattern is then passed
through the first quality control station where
it is thoroughly inspected for accuracy of design
and for any minor imperfections.
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The Lost Wax Process
The next step is to create a ceramic shell or
mold. We use a silicaceous slurry to cover the
wax model, and a special dry aggregate is then
applied to the wet wax mold using a fluidized
bed which blows the dry particles around in a
confided space, covering the wet area until no
more will adhere.
The molds are then heated to 1800 degrees F. to
melt the wax quickly to prevent the wax from
expanding, and cracking the mold. The molds are
then kept in the furnace at lower temperature
(250 degrees F.) until just before pouring the
metal. The temperature is then raised to 1200
-1400 degrees F. to burn-out any wax residue. The
place where the wax was, is now a void, hence the
lost wax designation.
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The Lost Wax Process
The ceramic mold stays preheated in preparation
to the pour and removed from the oven just prior
to the pour. The bronze metal, in ingot form, is
melted (up to 2000 degrees F.) in our large
furnace and then the molten bronze is poured into
the ceramic shell.
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The Lost Wax Process
After the metal is poured and cooled properly,
the ceramic shell (mold) is literally broken
away, using hammers and other hand tools. The
pour cup and feed system is then cut off and
ground away. The casting then enters another
inspection station to be reviewed for any
imperfections. Should the bell fail this
inspection the bell is sent back, melted and the
whole process starts again.
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The Lost Wax Process
After the metal is poured and cooled properly,
the ceramic shell (mold) is literally broken
away, using hammers and other hand tools. Removal
of fine particles is accomplished with sand
blasting. The pour cup and feed system is then
cut off and ground away. It then enters another
inspection station to be reviewed for any
imperfections. Should the bell fail this
inspection the bell is sent back, melted and the
whole process starts again.
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Final Inspection

• Before we deliver your Bellingham Bell we exact a
  3-point
• inspection. The final inspection being by the
  company
• President.

Only then can your Bell be registered in our
Archives as a Bellingham Bell.
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The Finished Product
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Your Bellingham BellYour Custom Fonts and/or
Logo with Color Enamel
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Hand Cast
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For any occasion
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Commemoration
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For Estate
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Your Bellingham Bell
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Can be what YOU want it to be
Call 1-800-802-3551 and design your custom
heirloom today