Question: How are bronze sculptures made? Bronze sculptures are made using the "Lost Wax" method. A mold is made from the original clay sculpture to produce a wax copy. The wax copy of the sculpture is coated with plaster or a ceramic slurry mix. The sculpture is then placed in a oven and the wax is melted out of the shell. While the sculpture shell is still hot it is placed in a sand box and the molten bronze metal is poured into the mold. After the metal cools the mold is removed from the casting. The bronze sculpture casting or castings are then cleaned, chased, and welded to complete the bronze sculpture. The final color treatment of the bronze sculpture is accomplished by application of chemicals and or colored pigments. All of the western bronzes sculptures cast for Broshears are molded from Broshears original clay sculptures.
Question: How much time does it take to make the original sculpture? It depends on the subject matter and the size. Most standing figures such as the Wyatt Earp bronze takes about three months to create. The Concord stage coach original made from wood and metal took a year to make. It consists of over two hundred parts that had to be molded and cast in bronze. The six horses for the stagecoach took another five to six months to create.
Question: How many bronze sculptures are made from the mold? The molds are capable of producing 50 or more wax copies of the original sculpture. Broshears large bronze sculptures are limited to 20 to 45 cast editions, depending on the subject. A few of the small bronzes in the $150 to $500 price range are limited 50 to 100.
Question: What is the difference between limited bronze sculptures made in the United States and Asian sculptures often sold in department stores? Bronze sculptures cast in the United States are sold by Art Galleries, representatives, or by the artist. The quality of each bronze sculpture is controlled by the artist and the foundry. Most if not all of the sculptures are cast within the United States. "Western bronze sculptures" by Robert Broshears are cast at Joseph Bronze in Oregon and Geffre Jewelry in Ephrata, Washington. Limited edition bronze sculptures are for the serious collector looking for quality and investment. Most high volume bronze sculptures marketed in stores and garden shops are made in foreign countries, mostly in Asian foundries at a fraction of the price. Foreign makers are able to produce the sculptures paying little to nothing labor wages to workers. These low quality sculptures are often copies of famous sculptures by Charlie Russell and Frederick Remington that are no longer protected by copyright laws; and in some cases illegal copies of copyright protected work. The cost of the metal used in the Asian bronze sculptures is the major difference in the retail pricing. The price of copper is high and still raising. Most of the foundries in the United States now charge a surcharge on top of the regular casting price. In the United States "Art Grade Silicon Bronze" is used by the foundries for casting. The Silicon Bronze alloy is 95% cu (copper), with 4% si (silicon), and 1% mn (manganese). The Asian bronze metal contains only about half the required copper content and unknown added metal alloys. This allows the Asian foundries to cast at a much lower material cost. The problem with the low copper content is the same as with some iron alloys; the metal can develope surface corrosion, lacks strength, is subject to cracking, and limits quality patina coloration.
Question: How is the bronze sculpture colored? The outside color of the bronze sculpture is called "patina". If the bronze is left to the natural elements of air and moisture the copper will develope a green color. The patina color applied to the bronze sculpture at the foundries is done by a combination of heat and chemicals. Liver of Sulfur and Ferric Nitrate produce the black, golds, reds, and browns. Another method of coloring the bronze sculptures is with pigment color, referred to as "polychrome color". After the bronze sculpture is patined it is sealed with clear wax or clear coat acrylic.
Question: What happens to the mold after the limit of the bronze sculpture editions is cast? The mold is destroyed.
Question: What is the price range of the bronze sculptures? The majority of the Western bronze sculptures, by Broshears, is 1/8 to 1/3 scale and are priced $1,500 to $8,900. The "Concord Stagecoach" , 1/8 scale, is priced at $8,600. The stagecoach has the option of adding a team of four to six horses and four passengers. The combined price of a stagecoach with a team of six horses, and the four passengers, is presently priced at $ 17,760.
Question: Are the bronze sculptures available for purchase at this time? Most of the western bronzes sculptures are in stock. There is about a two month waiting time if a new bronze casting from the foundry is required. The bronze sculptures are only cast two to five at a time due to foundry costs. Bronze sculptures not in stock, require a new order to the foundry with a 50% deposit.
Question: Are any of the sculptures cast with material other than bronze? All of the western bronze sculptures are cast in hot bronze, except for some of the special edition revolvers, Wyatt Earps badge, his revolver, and some spur rowels are cast in sterling silver. None of the sculptures are "cold cast" using resins, plaster, or plastic.
Question: What is a precast special? New sculptures that are still in the clay and have not yet been cast are offered at a discount. A 50% deposit is required. This provides a great opportunity for the collector and helps to pay up front foundry expenses.