Lost Wax Casting, Krofofrom, Ghana

Two methods of lost wax casting are done in Krofofrom. Both techniques begin with a wax model, but the method of filling the mold with metal differs. A wax model is made, it is covered with special mixtures to create a mold, the wax is melted out of the mold, then the cavity is filled with molten metal. The first method is demonstrated in Sokoban Krofrom (Krofofrom) by craftsmen at Providence Creation, P.O. Box 11592, Kumasi, Ghana. Telephone: 0244-524998 and 0243-818557. Email: ponsahgh@Ghanayahoo.com.

To make the model, wax is softened in fire.	Then the wax is pressed over a mold, and cut.	More wax is added to create the details.	They are melted with a hot iron to bond them.	Features are sculpted with a wood tool.


A wax thread is rolled out on a table, spiraled, cut in half, then pressed onto the face to form the ears.


Charcoal is pulverized, sifted, then mixed with water and clay to form a fine slurry that will preserve fine details. The wax models are dipped into it, bundled together so that several may be cast at once, then covered with more slurry. The wax rods (gates) will serve as channels for the molten metal.


A thicker slurry covers everything except the top of the wax.	Palm fiber is separated, mixed with clay, then sand is added to the mixture to form the outside of the mold.


The fiber and clay mixture covers the black core and is used to make a bowl-shaped top and another little bowl.		Scrap metal from earlier castings is cut apart, weighed, and then put into the small clay bowl (crucible).


The crucible is then attached to the mold with more clay and allowed to dry for a few days.	The dry molds are placed (with the metal side down) into a kiln and covered with a thick layer of charcoal. An electric blower is moved from hole to hole to gradually elevate the temperature. The wax will burn out and the metal will heat to a liquid.	After a few hours, the molds are removed, then turned over so that the metal will flow into the cavity.


Water is occasionally poured over the fire to cool the coals so that the molds that are deep in the kiln may be more easily removed with tongs.		A banana stem dipped in wet clay stops metal from leaking out of a crack.	After cooling, the molds are broken open; metal has taken the place of the wax.


The burnt black core is removed.	George Owusu removes rough spots with an electric grinder.		The pieces are then polished with soft lemons and a wire brush.	The result is amazing!

The other method of casting begins the same way at Mr. Afriyie's Gee Creation (P.O. Box X 397 F. N. T. Ksi., Kumasi, Ghana. Telephone: telephone 0244-791914 and 0242-238487), but metal is heated separately, then poured into the molds.

A hollow bead is made by covering a core with wax threads.	The wax is heated over a small clay stove.


The wax threads are made by pushing soft clay through an extruder (seen in the background).		The core (a mixture of water, clay, cow dung, and palm fiber) is covered with extruded wax threads.


As with the first method, the wax models are dipped into a slurry of water, clay and charcoal, bundled together, covered with more slurry, then covered with a coarser clay mixed with fiber.			Metal is placed in a crucible, then covered with charcoal. An electric blower helps raise the temperature.


The molds are placed top-town into a kiln, then heated for a few hours with wood until the wax melts out. Scrap plastic is thrown onto the fire right before casting to increase the temperature of the fire. The molds are then removed, turned upright on the ground, and filled with molten metal (brass with a little bit of aluminum). It's is ready to cast when blue smoke rises from the molten metal.			The last drop of metal is poured from the crucible (a recycled refrigerator motor housing).

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Web page, photographs, and text by Carol Ventura.