Now that we have designed and carved the patterns for our new Orchid Door Pull, we have moved forward to create 5 molds and have used these to create the wax replicas of the patterns. The waxes will be shelled in a ceramic coating and once fired the wax will be removed so that the hollow shells can be filled with molten bronze.
The new door handle has been designed so that the flowers and stem can either be upward or downward in direction, for as orchid enthusiasts know, this is indeed the way they grow in nature. To accurately depict the flower buds the stamen will be pointing downwards, as in nature, regardless of the direction of the plant the bud is always upward with the stamen downward so that bees and other pollinators can fly into the flower and gather pollen to perpetuate the reproduction of the plant.
While it takes more time and material to create 5 molds this enables us to cast the sections separately thereby determining the direction of the handle when the bronze castings are welded together and the location of the decorative supporting leaves is decided. The supporting leaves will always be welded at the “top” of the orchid handle or put another way at the point where the stem begins its growth.
The patterns were carved in basswood and then sprayed with a grey primer to fill in the grain of the wood so that successive versions would be smooth
Red wax replicas made from a silicon mold that was filled with hot wax, the wax once cooled is removed and the process is repeated to create a batch of flower buds. The stamens will be made separately using another mold and the process will be repeated to create as many stamens as there are buds. Once cast the bronze stamen will be inserted into the bronze bud and welded in place.