What happens during my products casting process?

PBR manufactures thousands of bronze plaques and associated products every month, each one individually handcrafted and cast. There are 8 stages within the production process:

  • Plaque Design – The layout of the inscription, motifs and other design features are keyed up (Contemporary) in computer programs, or hand set (Traditional) from information provided by our customer.
  • Negative Production (Contemporary) – The requested plaque designs are transferred to a photographic negative in an image setter.
  • Moulding - The patterns are placed in a mould box and covered with a thin layer of virgin sands. The remainder of the box is filled with a mix of silica sand and binder which hardens the mould.  The mould is then stripped and assembled to receive the molten bronze.
  • Pouring - Bronze ingots are melted to a temperature of around 1200 deg C. The molten bronze is poured into the mould and solidifies in the form of the finished plaque.
  • Fettling - The plaque is cleaned and excess bronze is removed from around the plaque.
  • Detailing - Required fixings are attached and any irregularities are eliminated.
  • Linishing and Painting - The plaque is painted the requested color in a spray booth. The raised surfaces is then ground with a belt linishing machine to bring up the bronze metallic color. A clear protective layer of paint is then applied.
  • Inspection and Packing - The plaques udergo a final quality inspection and are packed ready for dispatch.

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