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Lost-Wax Crystal Casting

The Crystal Sculpture Process

By Ferdi B Dick

I make each crystal piece by hand in small editions. The work is slow and exacting. Every surface is shaped, ground, and finished by hand. I use the lost-wax method to turn a 3D prototype into cast crystal. The wax is molded, invested in ceramic, burned out, and replaced with molten glass. After casting, I de-mold, cut, grind, sandblast, and polish until the form is clean and the surfaces read correctly.

Below is the step-by-step process. It shows the labor involved and why each sculpture is limited, technical, and truly handmade.

1) Create the prototype

I start with a 3D-printed prototype. It fixes the proportions and the surface flow. This model becomes the reference for every step that follows.

2) Make a latex mold and wax copy

I cast a flexible latex mold over the prototype. From that mold I pour a wax copy. Wax shows every mark, so I fettle and clean the wax until the surface is right.

3) Build the ceramic mold

I invest the wax in a refractory ceramic shell. The shell is baked in the kiln. The heat removes the wax and leaves a clean cavity that will take molten crystal.

4) Cast the crystal

I load measured crystal into the mold and fire it on a controlled schedule. Temperature and time are critical. Too fast and the piece will crack. Too cool and the details are lost.

5) De-mold

When the glass has cooled, I break the ceramic away by hand. This exposes a rough casting with sprues and kiln skin that must be removed.

6) Refine the form

I cut off sprues, grind high points, and chase details with hand tools. I remove every trace of ceramic from creases and undercuts.

7) Sand, polish, and sandblast

I go through a long sequence of abrasives from coarse to fine. Some areas I bring to a soft polish. Others I sandblast for a matte, light-holding surface. The contrast gives the form life.

8) Final inspection

I inspect the piece under strong light, correct any defects, and sign it. Only then does it leave the studio.

 

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