Lost wax casting is the process used for each Eaglador piece, cookware, cutlery or tableware. The metal is Kansa bronze, a copper-tin alloy (78% copper, 22% tin). The stages below run from the wax pattern to the mould, the pour and the finished casting.
An original model is meticulously sculpted from wax. This stage captures the sculptural lines that define our premium Kansa bronze cookware and cutlery.
A mould is created from the wax model… This precision ensures our luxury Kansa bronze items retain flawless forms.
Molten wax is poured into the mould and swirled to create an even 3mm coating, repeated for desired thickness. This step ensures the heavy gauge construction that defines our premium Kansa bronze cookware, delivering exceptional performance.
The hollow wax replica is carefully extracted from the mould. This delicate process preserves the integrity of our pieces, ensuring each premium heirloom item — from bronze pots and pans to high-end cutlery — embodies timeless sophistication.
Using heated tools, imperfections and parting lines are smoothed away, dressing the wax to mirror the final product. This chasing step refines the sculptural pattern of our heavy gauge Kansa bronze, guaranteeing a flawless finish that elevates gourmet experiences.
A tree-like wax structure is attached to provide channels for metal flow and air escape. This strategic setup is crucial for our luxury pieces, allowing the Kansa bronze to fill every detail without flaws.
The sprued wax is dipped in silica slurry and coated with crystalline silica stucco, building a ceramic shell at least half an inch thick. For larger pieces like our heirloom cookware bundles, we reinforce for robustness, aligning with our heavy gauge standards.
The shell is kiln-fired to harden and melt out the wax, leaving a precise negative space. This step prepares the mould for the infusion of our premium bronze alloy, ensuring non-stick patina development and ultra-conductive properties.
The cooled shell is checked for flow and sealed if needed. This rigorous testing upholds our standards for luxury kitchenware identifying any weaknesses.
Molten bronze is poured into the hot shell to prevent shattering, then cooled. This transformative moment brings Eaglador’s pieces to life .
The shell is broken away, revealing the rough casting. Sprues are removed for recycling, marking the start of refining our sustainable luxury items into polished heirlooms.
Air bubbles and sprue remnants are filed and polished away. This final chasing perfects the surface, readying our premium Kansa bronze for patina evolution — turning functional tools into sculptural art.
Every piece created through this ancient lost-wax casting process is built with exceptional care and structural integrity.
🏅 Backed by our 150-Year Heirloom Warranty, each Kansa bronze cookware piece and bronze cutlery item is protected against physical breakages and structural damage for 150 years from the date of purchase. This warranty reflects our confidence in the strength and longevity of traditional lost-wax casting combined with modern precision.
