Tag Archives: bronze

How It Works – Lost Wax Casting for Walter Bosse

Walter Bosse Hand Ashtray Casting Progression

Let’s dive into a little bit about the handmade casting process to understand a little more about what makes Walter Bosse and Vienna Bronze items special. The casting process used is “lost wax casting” or “investment casting.” Here all the steps and love that go into the creation of a Walter Bosse model:

Walter Bosse Hand Ashtray Master and Finished Model

1. Starting with a “master”

The process begins with the artist’s “master” pattern. There are several ways to make a master: A. directly from wax to mold; B. from wax to cast metal to mold; and C. from mold to master to secondary mold.

A. If we create a master out of wax and form a mold from it directly, the wax master could be melted down or damaged in the process. With this method, the master may be lost, along with the ability to create future molds from it. But at least we have one mold for the catalog.

B. Walter Bosse’s most common method of making a master was to sculpt the wax model by hand, create a metal cast from it, refine the metal model into a finished master, and then create a new mold. This way, the metal master is saved in order to continue making future molds. This is especially useful if the original molds get damaged or need to be replaced due to use over time.

C. If the master has been lost, but the mold is still available, we can cast from the existing mold, finish the model and save it for future mold making. The only downside is that there is about 1.52% shrinkage. (The general shrinkage allowance of brass is 3/16″ per foot.) We would not want to keep doing this over and over again, or the model’s size will continue to shrink with each new iteration. It’s good to keep a master with each mold if possible.

Walter Bosse Hand Ashtray Master to Wax to Mold

2. Making a mold

Rubber molds are preferred due to their longer shelf life. The creation of a rubber mold requires a vulcanizing press, which solidifies the shape using heat and pressure. Since quite a few of the original masters were lost, today remastering is often done with vintage Bosse pieces. In these cases, the vulcanizing process is less suitable, as the heat and pressure can be rough on vintage originals. Silicone molds are therefore used to preserve the quality of the vintage original (though the silicone molds do not tend to last as long). The vulcanized rubber molds end up lasting 1020 years with regular use, while silicone can last only 25 years.

It is necessary to cut a sprue hole in the mold, preferably somewhere inconspicuous on the model, running from the widest or thickest part to the thinnest part. This will be the path the wax/metal flows most easily into the mold. The master must then be cut from the mold, either by prying the mold open enough to remove the master, or cutting it in half entirely to make a two-part mold. It is best to cut the mold with a very sharp blade, such as a scalpel.

Walter Bosse Wax Tree

3. Wax

Molten wax is injected into the mold through the sprue hole. The wax model is then removed from the mold. An extended sprue is attached, which is then connected to a sprue base/post which makes up the center of the wax tree. We add as many wax models to the tree as possible to fill up all the available casting space.

Walter Bosse Casting Flask

4. Adding investment

Once the wax tree is full of models and ready to cast, it’s time to add the investment. The investment is what’s left when all the wax is burned out, leaving space for molten brass to be poured in. The flask/cuvette is placed around the tree. The investment medium, usually a type of plaster material, is mixed and added around the wax tree inside the flask. All of the bubbles must be sucked out, best performed with a vacuum or vibration method. Once the investment is cured, we are ready to burn out the wax.

Walter Bosse Casting - Molten Brass

5. Casting

The molten brass is poured, and begins to cure. Once the metal has cooled, the tree and investment material are removed from the flask. The investment is slowly and carefully broken away from the brass models. Once the models are fully cleaned of investment, they can now be snipped off the tree, ready for finishing.

Walter Bosse Finishing Process

6. Finishing

The models get a thorough grinding and polishing to ensure there are no flaws. They are then stamped on the bottom with “Bosse Austria,” and undergo the patented patina process. The model then goes through a second polishing in selected areas to highlight the gleaming beauty of the natural brass.

Walter Bosse Figurines

With finishing complete, a beautiful new Walter Bosse work of art emerges, ready to find a home!

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Sale is Up on Fab!

Hagenauer Bronze Logo
The latest sale is up on Fab today featuring a selection of beautiful Hagenauer figurines. My favorites are the little owl, fox and lounging bear. Check out the sale page here!

If you have any questions about the sale, please contact us and we will be happy to help!

Hagenauer Laying Bear Hagenauer OwlHagenauer FoxHagenauer Squirrel

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Vintage Collection Available!

Walter Bosse Vintage

We recently acquired a selection of vintage new-old-stock items cast in the 1960s in Germany and are now releasing them for wholesale. Due to the vintage sand-casting and hand-finishing methods, every item is slightly different. Quantities are limited so once they sell out, they are gone! Stock sheet available by request, just drop us a line!

Check out the collection below:

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NEW Walter Bosse Necklace Collection!

Walter Bosse Necklace Collection
We are excited to introduce a small collection of Walter Bosse necklaces in our Etsy shop. Each pendant is attached to black plated chain with lobster clasp closure, or adjustable-length waxed black cotton cord. Custom chain lengths are also available! Comes wrapped in a black velvet embossed bag with gold Certificate of Authenticity. More pictures of them below!

Walter Bosse Necklace Collcetion Walter Bosse Necklace - Cat Friends Walter Bosse Necklace - Ram Walter Bosse Necklace - Monkey

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Animal Menagerie Sale is Up on Fab!

Walter Bosse Vintage Menagerie

We are happy to participate in the newest Fab sale, Animal Menagerie. It is now live with a selection of vintage Bosse items from the 60s. Nice collection of vintage animals!

Check out the sale page here!

If you have any questions, please contact us and we will be happy to help!
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Limited Edition Custom Wooden Crates for Walter Bosse’s Hedgehogs

Walter Bosse Hedgehog Boxes
We aren’t able to share as much detail on the Fab sale so we thought we’d share some up close and personal photos of the boxes.

A little bit about the process: Each box is a custom made sliding lid wine box made of solid pine. We fitted the lid with some extra support struts and  hand painted the sides in matte black. The art was done with custom hand-cut Walter Bosse stencils. We think they came out pretty nicely!

Enjoy the gratuitous macro shots!

Water Bosse Custom Hedgehog Box Water Bosse Custom Hedgehog Box Water Bosse Custom Hedgehog Box Water Bosse Custom Hedgehog Box

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Custom Letterpress Certificates for Walter Bosse’s Hedgehogs

Walter Bosse Letterpress Certificates for Hedgehogs

Next up, we thought we’d share some up close and personal photos of the letterpress Certificate of Authenticity cards we produced specially for the upcoming sale.

A little bit about the process: Each card was hand printed with a Heidelberg Windmill on duplexed Eames solar white paper. The back was printed knockout in black and the front was printed with black and gold ink. The gold ink on the logo was then brushed with metallic gold dust, brushed with a feather an left to dry. The result gives it a unique textured metallic finish. Definitely a labor of love but we think it was worth it!

Enjoy more gratuitous macro shots!

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Bosse’s Hedgehogs on NOTCOT

Walter Bosse Hedgehogs on NOTCOT

Many thanks to Jean from NOTCOT for posting the video of our new Hedgehogs!

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Les Hérissons Noirs – Behind the Scenes Walter Bosse Hedgehogs Photos

Walter Bosse Hedgehogs Noir

Thought we would share some experimental behind-the-scenes shots for the newly released Bosse hedgehogs, their letterpress certificates and the wooden box. We decided to see how a black backdrop looked so we thought we’d call the set Les Hérissons Noirs.

I think they came out looking pretty classy! We probably won’t be able to use them anywhere but they are here for you to enjoy. What do you think? Better than the white backdrop?

Walter Bosse Hedgehogs Noir

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Walter Bosse Hedgehogs Noir

Stay tuned! This limited edition batch will be available exclusively through Fab.com starting on Friday, May 31st.

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Introducing the Walter Bosse Master Collection

We were recently given a very generous donation of vintage original masters by Walter Bosse and Herta Baller. These include bronze sculptures and everyday objects used for casting which are about 20% larger than finished items cast from these masters.

All have been sitting unused since the 1950s and came from the original collection of the Bosse/Baller company in Austria. Most are rusty from having been left in their raw state but some were given a patina and polishing. Most are very rough and were never used in production. A few items are completely finished items whose masters were lost, but the finished item was kept for later casting.

Enjoy the images below and in the Virtual Museum as well!

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