Lost Wax Casting Method

First a basic shape with simple details would be carved out of wood. This would then be used to mould an outer layer of plaster. Splitting the plaster in two to remove the wood, wax would then be used to fill the plaster mould. The wax would then be taken out and carved in greater detail by hand. The wax model would then be dipped into plaster and then baked, the wax melting away through specially shaped channels; hence the name ‘lost wax’. After this, molten brass would be poured into mould and the plaster broken and discarded. Finally, all the fine details would be carved by hand, polished and mounted onto the sword. Each fitting has to undergo this process individually and the moulds can only be used once, as they are lost in the process.