From Dull Mud to Shining Metal

The lost wax process is followed in the craft of making bell metal objects by using clay moulds.

Two kinds of moulds are used: those with an inner core to cast hollow articles, and completely hollow moulds to cast solid articles.

These moulds are entirely hand crafted. Here, the mould for a clay lamp is being worked on.

The core defines the basic form of the article, and is made using a variety of clays. It is then dried and polished.

The exact likeness of the article is made using beeswax, tree resin and castor oil.

The wax can be put on the core in the form of rolls, or applied in the form of sheets.

The moulds are broad on the top and narrow below. They are meant to provide a balanced inflow of metal later in the process.

The detailing and designs of the final products are crafted by hand onto the wax.

Copper connecting pins are hammered into the wax, acting as a support between the core and the outer mould.

A bell metal craftsman makes the mould for a temple lamp. The word ‘bell’ in bell metal indicates its connection with temple bells and lamps of many styles and sizes, all made for use in temples.

A craftsman shows the wax figures before they are cast in bell metal.

A variety of wax figures lie awaiting the next step in the process in the bell metal workshop.

A craftsman prepares the material to be used as a clay mould.

The process of bell metal work is skill intensive and performed with the simplest tools.

A craftsman prepares the final mould before casting.

The artisans traditionally belong to the Moosari or Kammada community.

Copper connecting pins are hammered into the wax, acting as a support between the core and the outer mould.

For the investment or outer layer of the mould, the wax model is covered in clay. Care is taken to cover all the details and corners of the wax model.

The clay covered wax moulds are dried in the shade for an entire day.

The vessel used to collect the wax after the process of de-waxing.

Women work as hard as men, even performing tough manual tasks. Here, a woman from the bell metal craftspersons’s family is preparing the ground for the process of de-waxing.

The senior male member prepares the mould for de-waxing.

The processes are dramatic, involving a number of workers, and the manual effort is strenuous.

The mould is almost ready for de-waxing now.

Dried coconut husks are used as fuel in the process of bell metal casting.

For de-waxing the object, craftspeople use dried coconut palm leaves as fuel to create the fire.

Circular clay funnels are made at various strategic points. The molten metal will be poured in from these openings.

This investment layer is left to dry for 24 hours.

During the process of de-waxing, the three-layered mould is heated on embers to melt the wax and vacate the space between the core and the investment layer. This will allow for the passage of the molten metal.

A thick layer of clay mixed with husk is applied on the dried moulds, leaving the runner points uncovered.

The fire has to be kept burning continuously, through the addition of palm leaves, to create stronger heat before the de-waxing starts.

The craftsman heats the mould before the de-waxing starts.

Heating the mould before de-waxing.

The openings through which the molten metal is poured in during casting.

The heated moulds are then inverted to remove the melted wax, which is kept for reuse.

The melted wax is collected in the vessel placed at the bottom.

Workspace and home life connect seamlessly for most bell metal workers who have production units on their own land.

The workshop has various activities going on. Here, the wax moulds are ready, waiting to be cast.

Read more about Bell Metal Casting here:

- Finishing Process
- A Range of Objects