swamimalai bronze and panchaloha idols manufacturer

lost wax process

The first stage of the statue creation process involves crafting a beeswax model of the selected figure. The wax is combined with tree resin and coconut oil, with harder wax mixture utilized for the body and softer wax for small details such as jewelry and trimmings. Specialists use a charcoal brazer to shape implements and small wax pieces while molding. In contrast to the past, present-day statutes above 16 inches tall are typically made hollow to save on shipping weights and conserve bronze material. The torso, head, legs, and arms are generally the hollowed areas. To create a 7-millimeter thick skin of the statue, the hollow mold is filled with a clay plaster mixture, usually poured via an opening at the top of the head, which is then sealed. The plaster-clay exterior mold is anchored to the fill with copper pins after the wax is removed, allowing for the molten bronze to pour in and create the final form. All statues can be poured solid based on discussed specifications during the ordering process.

Plaster and clay molding

After the completion of the wax model, the first layer of plaster is applied to the front of the statue, which is then kept to dry until it reaches the desired consistency. To strengthen the perimeter and crisscross the interior of the mold, reinforcing steel is bent and laid in accordance with the shape of the statue. Once the steel is in position, a second coat of plaster is applied to the mold and left to dry until it is properly set. The mold is then turned over, and the wax modeler performs final touch-ups to the figure while trimming the plaster to ensure a clean and even void-less seam between the two sides of the mold. After applying two layers of plaster and reinforcing steel, the mold is wrapped tightly with 4 millimeter wire, and a final layer of plaster is applied. The plaster mold mixture comprises of approximately three parts plaster, one-part rough sand, and one-part fine sand, primarily for statues up to 25 kg in weight. However, for statues over 25 kg, a clay mold is preferred, made from river bottom natural clay, mined from specific areas in the region, such as the base of the large Vishnu statue in the accompanying image. Using plaster expedites the process considerably because it hardens promptly, enabling subsequent coatings to be applied within two hours, depending on the outside air temperature. It is worth noting that the clay mold mentioned above took over three weeks to complete, from the time the wax modeling was performed until the application of the first layer of clay, reinforcing steel, and subsequent coatings, permitting the mold to dry entirely.

Losing the Wax

After the completion of molding, the Losing of the Wax process begins as per the casting schedule. The process involves melting the wax, baking the empty mold, and casting within a maximum of 30 hours. The molds are securely placed on a metal rack to keep the wax separate from the fire. This ensures the wax is saved and reused after filtration, and prevents it from catching fire. The process takes approximately 8 hours from setup to completion, as seen in the pictures above. After losing the wax, the molds are packed tightly and placed in a brick oven with a mud and straw top, where they are baked for 8-10 hours. This removes any residual wax and heats the mold to ensure the free flow of bronze during casting. This eliminates any potential obstructions and ensures the entire negative imprint of the statue wax is filled with bronze.

Casting the Statue

Once the furnace is operational and the bronze metal is heated to 1000 degrees Celsius (1820 degrees Fahrenheit), precise machine parts, high-quality scrap bronze, and pulleys are carefully fed into the crucible located in the forced-air forge. The final proportion of copper, tin, and zinc is kept confidential, but it is generally an 80-14-6 ratio. If the buyer wishes to request Panchaloha bronze with gold and silver, the proportion per kg must be specified. To maintain a stable mold temperature, baked statue molds are taken out of the oven and embedded in the casting area near the forge, which ensures a successful bronze casting process. The pouring process requires years of experience and involves high-energy and rapid movements. Castings are typically carried out during the night hours to allow freshly poured statues to cool and harden over the course of the early morning.

Rough cleaning and chiseling

After the casting process, the molds are excavated from the casting area and the plaster, reinforcing steel, and wire are meticulously removed. The statue is then further refined with a small scraper and soft wire brush on a drill. The majority of basic finishing is executed with flat files and a scraper, which requires numerous hours of skilled labor for an 18” statue. Following this stage, the statue is sent to the Master for precise hand chiseling and detailed work. The Journeyman statue craftsman receives the statue back to complete specified hand work such as crown, belt, sashes, and general finishes. The Journeyman craftsman is responsible for attaching the statue to the base and performing the patina work. This rigorous process ensures the exceptional quality of each statue crafted by our experienced craftsmen.

Final Detail chiseling and filing

The sculpture process begins with precise pencil marks and measurements, which will guide the Master and his son as they chisel intricate details into the bronze. This requires intense focus and dedication, as well as a considerable investment of time. The statue and base are poured separately, with the Master carefully mounting the figure onto the lotus flower pedestal after ensuring proper alignment and balance. The base boasts classic patterns and lotus petal detailing, typically square or rectangular in shape. Once the sculpture is securely fastened and perfected with expert hand filing, the Master hand-shapes the final persona of the face, applying a final patina and coconut oil to achieve a lustrous finish. Commissioned pieces may be modified with bright bronze or different patina types. To maintain the sculpture’s elegance, only minimal dusting and coconut oil touchups are needed.

Sthapathis in Swamimalai

The process of introduction to the work area of the Sthapathis in Swamimalai is an experience that should not be missed. The environment is full of activity, with the sound of the hammer blending with the pouring of molten metal to create a unique atmosphere. Professionals in the field of archaeology have found the concept of the ‘chaîne opératoire’ or ‘operational sequence’ to be an invaluable tool in understanding the technological stages and the social processes in craft production ranging from ancient to modern times.

In the case of the workers in Swamimalai, the chaîne opératoire plays a critical role in the analysis of their behaviors and techniques during metal production and transformation into culturally significant ritual objects. Understanding and recognizing the value of this tool will be essential for those interested in learning more about the rich cultural heritage of the region.

The history and cultural significance of the bronze icons produced in Swamimalai, India, date back more than 1100 years ago. Initially created for worship purposes, their popularity rose during the period of the Chola Dynasty, adding to their historical importance. These icons are not merely works of art but also serve as reminders of spiritual stories, meditation practices, and represent a cultural manifestation of Indian myths and legends. Each of these icons’ features and decorations holds a unique meaning that relates to the Indian epics of Ramayana and Mahabharata and depicts heroes from those legends.

The process of producing these Swamimalai bronze icons is quite intricate and precise. It utilizes the “lost wax” technique that complies with the guidelines of the Shilpa Shastra Manasara. The artists producing these pieces of art have passed down their techniques from generation to generation, ensuring that the legacy lives on.

Furthermore, in modern times, the Swamimalai bronze icons have become more economically significant, receiving the Geographical Indication Tag in 2008. This designation has expanded their market, and with a growing Tamil community abroad, these icons are used to build temples, further contributing to their demand. As such, it is evident that the Swamimalai bronze icons hold historic, cultural, spiritual, artistic, and economic significance both in India and internationally.

Swamimalai’s bronze icons are more than just beautiful objects. They possess an enchanting quality that makes them special to devotees. These icons depict the gods, goddesses, saints, animals, men, and women that are revered by the devotees.

What sets these icons apart is the expert craftsmanship that goes into each piece. The intricate designs are a testament to the skill of the artisans who make them. These works of art are made of a unique blend of metals that are believed to have medicinal and spiritual properties.

Further, the idols are believed to emanate positive energy after mantra chanting. They can be personalized in various finishes to suit individual preferences, adding to their aesthetic appeal.

To devotees, these icons are not mere objects but are seen as living gods that bring blessings to their homes. They can be found in temples and homes alike, where they are used for worship and decoration. Overall, Swamimalai’s bronze icons showcase the impressive talent of the artisans who created them and offer spiritual and aesthetic value to those who appreciate them.

Materials in their natural form before any processing or manufacturing.

Bronze icons made by Sthapathis in Swamimalai involve a complex process that utilizes a variety of raw materials. The raw materials used for making the icon include Kungulliam (resin), Mezhugu (paraffin wax), Wax-beeswax, and Kadalaiennai (groundnut oil). The mold is made using Kali Mann (clay), Vandal Mann (fine riverside clay), Manal (sand), and Karuvu (mould). The baking of the mold requires Bricks, Kari (coal), Rattai (dried cow dung cakes), and Sauku/kaatumaram (wood). Swamimalai bronze icons are made of an alloy of copper, zinc, tin, silver, and gold. Gold and silver have been gradually removed from the process due to economic reasons. However, many individuals still contribute their own gold and silver jewelry to be used in the icon production workshops. Currently, copper (82%), brass (15%) (an alloy of copper and zinc), and lead (3%)are used in making the icon. It is important to note that the bronze metal is an alloy made by smelting tin and copper together and led and zinc are also added in small quantities for the purpose of building statues.

Lots of different tools and technology.

The intricate and meticulous process of creating the renowned Swamimalai bronze icons is one that involves not only the skill of expert artisans, but also the use of an extensive array of tools and technologies. Beginning with the measurement of dimensions, a leaf strip or ribbon is utilized for precise calculations. A spatula is then employed for shaping and smoothing the wax model, followed by a knife for removing unwanted portions of the model. The use of a scraper enhances the sharpness of relief, while a foot rule ensures accurate measurements. A soldering iron, heated by fire, is deftly used to even out edges on the wax model. The hammer and chisel of varying sizes are then utilized for the painstaking process of chiseling any unwanted metal from the casting. The engraving tool comes into play and expertly carves out fine details, while files are used to smooth out any sharp edges on the casting. In the casting process, forceps are employed to handle hot crucibles, with an air blower/furnace used to build up the fire inside the furnace. The melting of metal for casting is achieved using crucibles, while kettles are essential to melt wax for pouring into moulds. The different sizes of tongs cater to varying crucible sizes, while ladles skim the hot crucible’s surface of slag and unwanted material. Finally, using a tala, the face of the image is measured, and after revealing, the polished metal image is smoothed with sandpaper, resulting in the breathtakingly beautiful Swamimalai bronze icons that are revered all over the world.

processing

Creating Swamimalai bronze icons is a meticulous and intricate process that requires various steps to be completed with utmost care and precision. The process begins with a meticulous melting of a combination of groundnut oil, resin, and paraffin until the mixture forms a workable consistency that can be molded into the desired idol shape. Once the wax model is completed, it is weighed and subjected to both solid and hollow casting techniques to make the final sculpture. The next step involves creating a mold by applying precise layers of clay and sand which cover every nook and cranny of the wax idol. The addition of runners and a metal wire to the mold makes it ready for the wax removal process where the mold is continuously heated. The mold is then made to undergo baking to ensure its preparedness for metal pouring. After melting the necessary metals, the hot metal is poured into the cooled mold and left to cool. Finally, once the mold is broken, the finished idol is detailed and polished.

Swamimalai bronze icons are truly a sight to behold. These exquisite pieces are meticulously crafted with great precision and a keen attention to detail. Each icon is available in various sizes and may depict different Hindu deities, including the beloved Ganesha, Subramanya, Rama, Krishna, Vishnu, Lakshmi, Parvathi, Saraswathi, Hanuman, and many more.

The techniques involved in creating these icons are diverse and intricate. Each deity is designed to be depicted as standing alone or in pairs or groups, often accompanied by their ornate accessories like conches, rosary beads, or musical instruments. These icons are created using the Shilpa Shastra measurements system, which includes units of measurement such as the angula, a measure that is divided into eight yava and with the smallest paramanu.

Bronze casters, known as Sthapathis, work tirelessly to combine deep scriptural knowledge with their creativity, resulting in each icon being a unique and incredibly special piece of art. The workshops producing these icons range from heredity family workshops to individual skilled craftsmen and entrepreneur-owned workshops.

Ultimately, understanding the symbolism behind each deity through iconology enhances the significance of the Swamimalai bronze icons, elevating them to become more than just beautiful pieces of art but spiritual representations of beloved Hindu deities.

Bronze icon production has been a form of craft that requires a high level of attention to detail and craftsmanship. The icons themselves embody perfection and are seen as symbols of worship that have been created through a detailed process. However, one small mistake during this process could render the entire icon defective or not up to the mark. The loss of time and materials, specifically, is immense in this particular industry. Due to the fact that the clay model cannot be inspected after it has been baked, achieving precision can be extremely difficult resulting in a great deal of waste.

However, a lesser-known but crucial component of the icon production process is that of recycling, which aims to retrieve brass and copper for workshops. This method, known as Manalasubhavar in Tamil, involves on-site recycling of all left-over metal from major workshops. A mud-cleaner is employed to perform the task of extraction of the metal bits and lumps that have been buried in the casting floors of the workshops and cleansing of the metalliferous slag deposits in the crucibles. The amount of casting work determines the contracts taken by the mud-cleaner. In the end, the metal collected is melted and cast into large open molds to form ingots and stored for later re-melting and casting. It’s essential to understand the work of the mud-cleaner to recognize the intricacies in the organization of a traditional metal workshop.

The Chola dynasty was one of the most significant and influential dynasties in South India, reigning over the region for an impressive 400 years from the 9th to the 13th century. During this time, the Chola kings became known for their remarkable contribution to the arts, particularly their commissioning of sculptures and temples dedicated to Hindu deities. This was their way of displaying their power and wealth to the world.

One of the greatest Chola kings was Rajaraja Chola, who made history with his construction of the Temple of Thanjavur. This impressive temple is regarded as one of the most magnificent examples of splendid architecture in India. To complete the construction of this grand structure, Rajaraja relied on the Vishwakarma community of Sthapathis, who were highly esteemed as master carpenters and builders in traditional Indian sculpture.

The Sthapathis were exceptional at creating complex metal icon production and had a vast knowledge of religious traditions. They were not ordinary craftsmen, but true artists and experts in their field. Following this project, the Sthapathis settled in Swamimalai due to its rich alluvial soil. It was here that they established themselves and their craft of bronze icon making, which has become renowned ever since for its exceptional quality and beauty.

The production of traditional handicrafts such as the bronze icons of Swamimalai requires a great deal of effort and dedication. The intricate crafting process of these artifacts is every bit as challenging as the process of documenting them for exportation. One of the biggest hurdles that must be overcome is the need for accurate documentation, which often takes many months. This delay can cause potential buyers to lose interest in the products, leading to a decline in sales and revenue for the Sthapathis, or traditional bronze artisans. Additionally, middlemen sometimes play a role in the business, purchasing products directly from the Sthapathis and marking up the price, thereby hurting both the artisans and the buyers.

Another challenge faced by the bronze icon industry is the proliferation of fake or duplicate products. Despite these challenges, the bronze icons created in Swamimalai continue to be an integral part of Indian tradition. Fortunately, support exists in various forms, such as from the government, with the Tamil Nadu State Corporation, and from private companies. This support recognizes and acknowledges the value and significance of the bronze icons and the skill of the Sthapathis who create them.

It is not just external support that the Sthapathis receive. The artists are also recognized for their work and are awarded at state and national levels, bringing them intrinsic and extrinsic rewards. Despite the many obstacles that exist, the future looks bright for the Swamimalai bronze icon industry, as it continues to remain significant and valued in Indian culture.

OUR MISSION

Cholabronzesculpture (Vitri Eswari Sirpa Nilayam) is dedicated to delivering more than just a beautiful bronze statue to our clients. We offer a unique experience that allows individuals to purchase a personally crafted piece directly from the artist who has dedicated their skill and craftsmanship to perfecting it. Our use of the centuries-old Chola Lost Wax Bronze statue craft further enhances the value of our pieces. We believe that supporting local artists strengthens the roots of South Indian cultural heritage, and we take pride in offering our clients the opportunity to connect with the artist responsible for creating their treasured masterpiece. Our pricing is based on actual costs plus a fair profit, and we aim to support the families of our artists with every purchase. Our business model allows us to focus our attention on the creation of truly unique and beautiful pieces, rather than supplying high-priced retail outlets.