While much of what we cast is visually dramatic where possible we like to add a textural note to our Luxury door hardware. The lost wax method of casting is perfect for creating deeply textural pieces that would be almost impossible to achieve with less expensive casting methods such as sand casting. The depth of a particular detail is limited only by the pattern makers skill and by the gravity flow of the molten metal.
The pattern is the 3 dimensional original and is the starting point for the casting. The mold is made from either a latex solution that can be brushed on or from a catalytic 2 part silicone solution that can be poured over the pattern. While both solutions take an almost perfect impression from the pattern, the latex solution will require several layers and will require a more rigid casing to support the floppy mold.
The Willow heroic door pull is a good example of the type of detail and texture that can be achieved from a silicone mold that was made from the pattern above. The pattern was carved by Martin in bass wood which is a pale and tightly grained wood and then painted with a grey primer to more clearly reveal any imperfections and to also help fill in any pores in the wood grain. The undulations in the leaf tendrils left good impressions in the mold and the result is a casting that is an almost perfect facsimile of the original but when rendered in bronze creates a stunning door handle.
Section of the pattern with grey primer to show any imperfections and to fill the wood grain