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Techniques:

Metal Casting

Casting is an essential phase of our production cycle – an ancient technique dating back to the 4th millennium BC – with which we create works of art by shaping molten metal in molds.

We use the earth casting technique, also known as staff casting, in which the model is impressed upon special clays compacted within steel frames.

 

Techniques:
Metal Casting

Casting is an essential phase of our production cycle – an ancient technique dating back to the 4th millennium BC – with which we create works of art by shaping molten metal in molds.

We use the earth casting technique, also known as staff casting, in which the model is impressed upon special clays compacted within steel frames.

TECHNICAL DESCRIPTION

The staff casting technique allows for the reuse of molds: a durable model is inserted into a “staff” composed of two interlocking steel frames, into which refractory clay is pressed to create a negative form. Once the model is removed, the molten metal is poured into the cavity, filling every space to faithfully reproduce the design.

This technique is ideal for models with low relief and no undercuts, but it can also be applied to high-relief pieces with exceptional skill. In such cases, clay plugs secured with metal pins are used at the undercut points, ensuring the precision of the final result.

Another traditional method, now obsolete, is cuttlebone casting, which was once used for simple models without undercuts. This refractory material was able to retain the shape of the model even when exposed to the extreme heat of molten metal without immediately burning, making it ideal for small artisanal works. Although effective for small-scale craftsmanship, this technique has gradually been replaced by more advanced and versatile methods.

TECHNIQUES AND PROCESSING

Every metal has a unique soul

At Marco Riccardi’s laboratory, we have been bringing to life objects with sophisticated and captivating designs for years, using the finest processing techniques for bronze, copper, brass, and steel. Each metal requires a specific approach, adapted not only to its properties but also to the desired final effect.

Expertise and experience are essential to ensure results that fully satisfy our clients. We collaborate with the finest artisans, who, with precision and mastery, produce impeccable works of great aesthetic value, transforming each piece into a unique work of art.

1
Bronze
Bronze processing techniques, rich in history and tradition, revolve primarily around the ancient method of negative mold casting, which is still used today with technological innovations. Over time, new materials such as polystyrene, silicone, and thermosetting resins have been integrated into the process, while the basic technique remains unchanged. The main stages of the process include:
  • Model Creation
  • Mold Creation
  • Mold Firing (during which the model can be either lost or extracted)
  • Pouring of Molten Bronze
  • Finishing
The process involves melting the bronze and pouring it into a mold to give it shape. Once solidified and removed from the mold, the object is finished cold to achieve an impeccable result.
The various techniques differ based on the material used for the mold and the model. For example, in the traditional lost-wax technique, the wax model is covered with a refractory material such as clay. During firing, the wax melts away, leaving an empty mold ready for the bronze pour. In this process, both the model and the mold are destroyed.
Other techniques, such as sand casting, allow the model to be preserved for future reproductions by removing it prior to casting. Once the process is complete, the object can be further enhanced with surface treatments such as gilding, nickel plating, chrome plating, silver plating, browning, and bronzing, which add aesthetic value and protection.
2
Brass
The production cycle of brass follows precise and meticulous phases that, through unique techniques, lead to the creation of a high-quality final product. Here are the steps involved in the process:
  • Material Selection
    Choosing the type and dimensions of brass profiles according to the project’s technical specifications.
  • Cutting
    I The profiles are cut to size with a cutoff saw, following the design guidelines.
  • Bending
    I The profiles are shaped either using a tube bender or manually, employing heat.
  • Drilling
    Some profiles are drilled using an electric drill.
  • Milling and turning
    Removal of metal chips through the rotational action of the tool and the workpiece.
  • Grinding
    Preparing the profiles for subsequent phases such as welding, assembly, and polishing.
  • Welding
    Assembling the materials on workbenches using techniques such as brazing with silver alloy, tin soldering, or TIG welding.
  • Finishing
    Removing any imperfections resulting from welding and cleaning.
  • Polishing
    Eliminating residues from previous stages.
  • Accessory Fabrication
    Creating small details directly on the final product.
  • Final Assembly
    Mounting the accessories and profiles to complete the piece.
At the end of the process, the object can be further enhanced with galvanic and chemical treatments - such as gilding, nickel plating, chrome plating, silver plating, browning, and bronzing - which provide both an aesthetic touch and lasting protection.
3
Copper
Copper processing has ancient roots dating back to prehistory: the oldest copper object, a small pendant, was discovered in the Shanidar cave in Kurdistan and dates back over 12,000 years. In Italy, the first traces of copper working appear around 4000 BC, marking the beginning of a tradition that our artisans continue with passion and expertise.
One of the most refined techniques is copper engraving and embossing, which involves several stages:
  • Engraving
    A design is etched onto a thin copper sheet using pressure. Specific tools are used to create reliefs, transforming the sheet into a bas-relief sculpture.
  • Consolidation
    The three-dimensional sheet is affixed to a wooden support structure to achieve the desired artifact.
  • Patination
    Non-toxic acids are applied to create a “naturally” artificial coloration, giving the copper an antiqued, bronzed appearance.

To bestow copper and its alloys with an antique aesthetic, chemical treatments that mimic natural aging can be employed. Using the same techniques as with brass, we also craft decorative objects such as chandeliers, wall sconces, and lanterns, combining functionality with design.
At the end of the process, the object can be further enhanced with galvanic and chemical surface treatments—such as gilding, nickel plating, chrome plating, silver plating, browning, and bronzing—which accentuate its beauty and ensure lasting durability.
4
Steel
Using the best semi-finished materials available on the market, our technologies allow us to work steel through every stage of its processing with extreme precision, creating sophisticated and high-quality design objects. The professionalism of our team and daily innovations contribute to making each creation unique and cutting-edge.
Metalworking always starts with "semi-finished" materials—blocks of various shapes and sizes that, through specific techniques, are transformed into the desired lines and forms. The main steel processing techniques include: )
  • Cutting
    Performed with abrasive discs or shears to obtain the basic shape of the semi-finished material.
  • Stamping
    Machines with "male" and "female" molds are used to imprint a precise shape onto the semi-finished material.
  • Bending
    Used to shape the sheet metal and achieve specific curves and angles.
  • Milling and Turning
    Techniques that remove metal chips by using the rotational movement of the tool and the workpiece to accurately shape the steel.
These techniques, combined with the expertise and attention to detail of our team, allow us to transform steel into impeccable design pieces that blend functionality and aesthetics.

Bronze processing techniques, rich in history and tradition, revolve primarily around the ancient method of negative mold casting, which is still used today with technological innovations. Over time, new materials such as polystyrene, silicone, and thermosetting resins have been integrated into the process, while the basic technique remains unchanged. The main stages of the process include:

  1. Model Creation
  2. Mold Creation
  3. Mold Firing (during which the model can be either lost or extracted)
  4. Pouring of Molten Bronze
  5. Finishing

The process involves melting the bronze and pouring it into a mold to give it shape. Once solidified and removed from the mold, the object is finished cold to achieve an impeccable result.

The various techniques differ based on the material used for the mold and the model. For example, in the traditional lost-wax technique, the wax model is covered with a refractory material such as clay. During firing, the wax melts away, leaving an empty mold ready for the bronze pour. In this process, both the model and the mold are destroyed.

Other techniques, such as sand casting, allow the model to be preserved for future reproductions by removing it prior to casting. Once the process is complete, the object can be further enhanced with surface treatments such as gilding, nickel plating, chrome plating, silver plating, browning, and bronzing, which add aesthetic value and protection.

The production cycle of brass follows precise and meticulous phases that, through unique techniques, lead to the creation of a high-quality final product. Here are the steps involved in the process:

  • Material Selection: Choosing the type and dimensions of brass profiles according to the project’s technical specifications.
  • Cutting: The profiles are cut to size with a cutoff saw, following the design guidelines.
  • Bending: The profiles are shaped either using a tube bender or manually, employing heat.
  • Drilling: Some profiles are drilled using an electric drill.
  • Milling and Turning: Removal of metal chips through the rotational action of the tool and the workpiece.
  • Grinding: Preparing the profiles for subsequent phases such as welding, assembly, and polishing.
  • Welding: Assembling the materials on workbenches using techniques such as brazing with silver alloy, tin soldering, or TIG welding.
  • Finishing: Removing any imperfections resulting from welding and cleaning.
  • Polishing: Eliminating residues from previous stages.
  • Accessory Fabrication: Creating small details directly on the final product.
  • Final Assembly: Mounting the accessories and profiles to complete the piece.

At the end of the process, the object can be further enhanced with galvanic and chemical treatments – such as gilding, nickel plating, chrome plating, silver plating, browning, and bronzing – which provide both an aesthetic touch and lasting protection.

Copper processing has ancient roots dating back to prehistory: the oldest copper object, a small pendant, was discovered in the Shanidar cave in Kurdistan and dates back over 12,000 years. In Italy, the first traces of copper working appear around 4000 BC, marking the beginning of a tradition that our artisans continue with passion and expertise.

One of the most refined techniques is copper engraving and embossing, which involves several stages:

  1. Engraving: A design is etched onto a thin copper sheet using pressure. Specific tools are used to create reliefs, transforming the sheet into a bas-relief sculpture.
  2. Consolidation: The three-dimensional sheet is affixed to a wooden support structure to achieve the desired artifact.
  3. Patination: Non-toxic acids are applied to create a “naturally” artificial coloration, giving the copper an antiqued, bronzed appearance.

To bestow copper and its alloys with an antique aesthetic, chemical treatments that mimic natural aging can be employed. Using the same techniques as with brass, we also craft decorative objects such as chandeliers, wall sconces, and lanterns, combining functionality with design.

At the end of the process, the object can be further enhanced with galvanic and chemical surface treatments—such as gilding, nickel plating, chrome plating, silver plating, browning, and bronzing—which accentuate its beauty and ensure lasting durability.

Using the best semi-finished materials available on the market, our technologies allow us to work steel through every stage of its processing with extreme precision, creating sophisticated and high-quality design objects. The professionalism of our team and daily innovations contribute to making each creation unique and cutting-edge.

Metalworking always starts with “semi-finished” materials—blocks of various shapes and sizes that, through specific techniques, are transformed into the desired lines and forms. The main steel processing techniques include:

  1. Cutting: Performed with abrasive discs or shears to obtain the basic shape of the semi-finished material.
  2. Stamping: Machines with “male” and “female” molds are used to imprint a precise shape onto the semi-finished material.
  3. Bending: Used to shape the sheet metal and achieve specific curves and angles.
  4. Milling and Turning: Techniques that remove metal chips by using the rotational movement of the tool and the workpiece to accurately shape the steel.

These techniques, combined with the expertise and attention to detail of our team, allow us to transform steel into impeccable design pieces that blend functionality and aesthetics.