How are your pieces made?

We use the lost wax casting method for all of our sculpture. Each piece is designed in wax initially. We use silicone rubber molds to reproduce pieces and keep consistency. A structure is built around each wax pattern to ensure proper proper flow of the bronze during casting. Once the mold is finished with sprues and vents, a ceramic shell mold is build around the wax by building up layers of sand and slurry. Once the ceramic shell reaches the proper thickness it is left to dry. Once the ceramic shell is dry, the wax can then be melted out. At this point the molds are all fired in a kiln to remove any remaining wax. When the time comes to cast, the molds are fired in the kiln to proper temperature as the bronze is melted in our blast furnace. Once both elements have reached the desired temperature, the molds are removed from the kiln and bronze is poured in while still hot. Once the molds have cooled, the ceramic shell is broken apart and inside is your pattern in bronze form. Sprues and vents are removed to be remelted for later pours. The bronze pieces are assembled by torch welding or silver soldering, leveled, and any necessary details are chased back in using small die grinders. Once the chasing process is complete, the artwork is patinaed using liver of Sulphur, dried, then buffed to add depth to low spots and shine to high spots. All bronzes are coated with Incralac, a clear-coat designed specifically for bronze to prevent tarnishing.

How long does the process take?

This has always been a difficult question to answer. Some pieces are larger and require assembling post casting. Some designs are intricate and take days of working the wax form to finish. The simple answer is two weeks to a month depending on the design. Some pieces may take longer due to various factors such as weather, outside temperature, assembly procedure, and casting failures.

How long have you been doing this?

Butch Honeck has been in the business of casting bronze for over 50 years.

How did you get started?

After a skiing accident which left Butch’s leg in a cast and stuck at home, he began welding steel sculpture to occupy his time. He attended a show and sold all of his inventory. Later on he discovered the art of casting and has never looked back. He calls the skiing incident his lucky break.

Do you ship outside of the country?

Unfortunately due to past headaches and losses we do not currently ship our artwork outside of the United States.