How are bronze plaques made?

The manufacturing process

At Anglia Sign Casting, craftsmanship is at the heart of everything we do. Using nothing more than raw materials, we shape something truly lasting. Discover the process behind our work.

Pattern-making

Once the design is finalised, the pattern-making process begins. Crafted from various materials such as wood, plastic and photopolymer resin, the pattern serves as a prototype for the final piece, which will ultimately be cast in bronze.

Any imperfections in the pattern will subsequently appear in the casting, making it imperative for the pattern-makers to scrutinise every detail with the highest level of care.

Moulding

The pattern, once complete, is placed in a moulding box. A layer of specialised facing sand is evenly distributed across the pattern's surface to achieve a smooth and detailed finish. The process is completed by tightly packing "green sand" around the pattern to strengthen the mold during casting.

Pouring the metal

Heated to temperatures exceeding 1200°C, molten bronze is prepared in a furnace before being poured into the sand mould. Though it may seem straightforward, foundrymen must exercise great precision when pouring the molten metal, ensuring it fully fills the mould. They employ various techniques to eliminate air bubbles, preventing defects and achieving a flawless cast.

Knocking out

"Knocking out" is the process of carefully removing the cooled casting from its sand mould. Once extracted, the mould is broken apart, and the sand is prepared for reuse.

Fettling

Although we’d love each casting to emerge flawlessly, some finishing touches are always needed. Every stage of the process calls for a keen eye for detail. The bronze is sandblasted to remove any remaining sand, and all excess casting components such as sprues, runners, and gates are carefully taken off. After that, the edges are sanded and the lettering is linished to achieve a sharp and refined appearance.

Powder coating

For the final finishing touch, our bronze plaques are painted using a durable powder coating system. Once the first layer is oven-cured, the plaques undergo a meticulous second stage of linishing, carefully removing select areas of paint to unveil the lustrous sheen of the metallic lettering. To complete the process, a layer of high-gloss acrylic lacquer is carefully applied, preserving the brilliance of the exposed lettering and ensuring its beauty withstands the test of time for generations to come.

Ready to bring your vision to life with a beautifully handcrafted bronze plaque? Contact us today to discuss your design and create something timeless.