The lost wax casting process has been widely practiced in Africa for many centuries.  West African sculptors were casting gold, bronze, and brass with this process from around 900AD, and it is believed that the process was introduced from the north by trans-Saharan traders.

The lost wax casting process is quite amazing and extremely clever.  It is so complex and labour intensive that it is remarkable that the tradition has survived.

The production process:

• The first part of the process is to create and shape a design from bees wax.  The wax model is an exact replica of what the finished brass product will look like.  Each object is made individually, which means that no two are the same and there will always be variations between similar objects.  Bees wax is used because it not only has a low melting point but is also soft enough to carve fine details and is hard enough to retain its shape.
• The shape is then dipped in a paste made from finely ground charcoal, clay and water, then left to dry in the sun.
• When the shape is dry, it is again dipped in a paste – this time made from coarsely ground charcoal, clay and water.
• A number of similar sized shapes are joined together using more of the charcoal, clay and water paste.
• One piece of wax thread is joined to each individual shape.  These form a channel to the wax shape so that the brass can pour into the space left when the wax melts.
• Palm fibre and clay is coated around the conglomerate of shapes to strengthen it.
• Crucibles are made that fit over the finished moulds and filled with brass.  A variety of brass can be used, recycled keys, padlocks, and terminals from car batteries. The brass-filled crucible is then attached to the mould and covered with more palm fibre and clay mixture then left to dry in the sun.
• The moulds are now ready to be placed in a trench kiln where they are fired.  As the moulds heat up the bees wax melts, as does the brass.  The melted brass then fills the shape left by the melted bees wax.
• After the moulds have been baked in the kiln they are broken open to reveal the brass pieces inside.
• The long task of cleaning each piece then commences - the best way to clean your brass is with lemon juice!


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