Advanced Jewelry and Design

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1 Casting Project –Low Relief Wax Carving
Sketches:
Sketch 7 to 8 ideas that could be taken out of a block of wax that is no larger than 1 1/4 x 1 1/4 x 3/8.

Final Layout: The final drawing will need to be drawn exactly the way you want to
carve your piece.

Draw final drawing on Casting Action Plan Worksheet so that we can reduce it to the
size of the wax. To receive credit for the final drawing it will need to be on this
worksheet.

You will need to show multiple views in the same scale so that the dimensions can be
carried over to your carving.

It is important to note centerlines, and plan your project so that it is square and level.
Use templates, and rulers where it is necessary.

Low Relief Wax Carving Project

If you cut your wax sheet from a larger block of wax, smooth out all your ridges, making your piece smooth and level,
and square, this is done by using a heavy toothed flat file. Make sure your wax is well supported and on a flat surface, or
you will stress the wax and possibly break it.

Transfer your design to your wax:

Pricking many points through your drawing can plot your design out. Another method is covering the wax with a
white china-marker, then you can make a carbon copy by rubbing drawing graphite on the back of your drawing, then
redrawing over your lines of your drawing, thus transferring it into your wax. When drawing, you want to scratch into the
wax a bit. Paint tempera into your lines, then it will be easy to see and follow.
 Sawing: Trim outside the perimeter with enough room to file down to your
line. A twisted saw blade can be used to do rough cutting, but be careful,
because the kerf is much wider.
 Drill holes in negative space for sawing. Never try to jab through
though the wax.
 Sawing now should be done with a #4 saw blade that is not twisted.
This will allow you to come closer to your line.
 It is extremely important to keep your saw blade straight up and
down (90 degrees) when cutting.
 Tip: work at the proper height, and eye level. Otherwise you will
over cut either the bottom or top.
 Saw slow and steady. Too much friction melts the wax behind your
sawing.
 Do not try to execute really sharp turns, or corner angles with the
saw. Save sharp points for filing and knife work.

Filing: The first filing should also be done at working with your file at
90 degrees on a v block (work should be flat and level).
 File the outside first.

 Keep checking the reverse side for accuracy.

 Then, file your thickest areas of your interior design first.

Saving the more fragile areas to be developed afterwards.

 After your first filing, you may start to refine your design with
and x-acto blade or scrapers by scraping and working gradually
into corners.

 Never cut like you are cutting a chunk of cheese…you will

crack your wax!

 Hold the knife at 90 degrees and work into your piece.

Once you have your silhouette determined, the highs and lows of your surface can start to be worked on:

o Begin by scribing overlaps and contour lines that separate

areas on your piece.
o This creates a cut-stop. Scrap away slowly unwanted area.
Repeat this procedure until all the level of your carving are
exposed.
o Start to round off the wax to the appropriate angles by using
a file, or continue refining by scrapping with a knife.
o Tip: Don’t curve to the bottom plane or it will end up a
sharp edge when it is in metal.
o Wax is fragile, Keep work supported!

When the basic carving is done:

 Lightly sand to get ride of marks.
 If necessary, reduce the mass of wax from the back.
Metal should not be thinner than 20 gauge metal.
 Do a final hand polish over the wax with a piece of
hard felt.
 You are now ready to attach the sprue to wax and prepare for casting 