Big copper age cast copper product production process

**The Big Copper Age: Handcrafted Copper Art Production Process** During the Big Copper era, every copper casting was a labor-intensive and artistic creation, requiring 12 meticulous and time-consuming steps—each one done by hand. This traditional craftsmanship ensures that every piece is not just a product, but a true work of art, blending history, skill, and beauty into a single masterpiece. One of the key stages is **clay sculpture**, where each product begins with a prototype made from earth. The sculptor carefully refines the design through multiple trials, ensuring that the form, expression, and details are perfect. Since this step directly influences the final quality, our sculptors are among the most skilled in the industry, known for their precision and creativity. Next comes **silicone mold making**. Using a high-quality chemical material called Likang Silicon, the mold captures even the finest details—so precise that it can reflect the thickness of a hair. This allows for an exact replication of the original sculpture. Then, a **resin prototype** is created by filling the silicone mold with polyethylene (also known as Boli Polyethylene). This resin model serves as the base for further production. After that, the **resin embryo is trimmed** to refine its shape, texture, and surface. This stage involves careful grinding and adjustment to ensure the model is ready for the next step. A new **silicone mold is then made** from the finished resin model, allowing for repeated use in future castings. Next, a **paraffin prototype** is produced by injecting melted wax into the silicone mold under pressure. This wax replica accurately reflects the final product's shape and structure. The paraffin prototype is then **refined** to remove any imperfections, such as mold lines or minor damages. This step is crucial, as it directly affects the final appearance and quality of the copper piece. The next process is **sand mold (ceramic shell) production**. Multiple wax prototypes are attached to a tree-like structure and dipped repeatedly into a special mud or stone pulp. After several layers, the shell becomes about 9mm thick (5–7 layers). The wax is then melted out using high heat (140–160°C), leaving behind a hollow ceramic shell. Once the shell is ready, it undergoes **sintering** in a high-temperature furnace at around 800°C, strengthening the structure and preparing it for casting. In the **casting** process, the hollow ceramic shell is placed into the furnace again, this time at temperatures between 800°C and 1000°C, depending on the alloy used. Molten copper is poured into the shell, and after cooling, the ceramic shell is broken away, revealing the rough copper casting. The final stage involves **finishing and processing** the casting. This includes sanding, cleaning, cutting, grinding, heat treatment, shaping, machining, and polishing to bring out the desired form and texture. Lastly, the **surface is treated and protected**. Depending on the desired effect—antique, polished, or other finishes—the surface is colored and enhanced. Finally, a layer of wax is applied for protection and a final polish, completing the masterpiece. This entire process, rooted in tradition and executed with precision, showcases the dedication and artistry of the craftsmen who bring these copper creations to life. **Submitted by:** http://news.chinawj.com.cn

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