Rocky Mountain Door Hardware

12 13 The Art of Creation THE ART OF CREAT ION The art of sculpting molten bronze into intriguing silhouettes dates back thousands of years. Today, our highly skilled artisans draw up the same time- honored traditions that have been passed down through the generations to handcraft hardware and accessories of uncommon beauty and enduring style. Using Old-World casting techniques, each product touches no less than 30 hands, undergoing a rigorous 20-plus-step process that starts in our pattern shop. An expert craftsman begins by hand sculpting imaginative ideas into pattern boards to create casts using sand or wax. SAND CASTING Sand is compacted tightly to both sides of the pattern board. Once set, the boards are removed, and each half of the mold is carefully inspected. The halves are placed back together, forming a cavity to hold the molten bronze. Next, 300 pounds of bronze ingots are melted in a crucible, reaching a temperature of 2,200°F. The bronze is poured by hand into the casts and left to cool. After cooling, the product is removed and sent on for finishing. LOST-WAX CASTING For designs that are a bit more intricate, the art of lost-wax casting is employed. This process is extremely time intensive as the wax molds are dipped in a ceramic slurry multiple times and must dry completely between each dip. The molds are placed in kilns to harden. Then, hot molten bronze is poured into the cavity. Once hardened, the shell is cracked off by hand to reveal the bronze piece nestled inside. STATE-OF-THE-ART MACHINERY After the casting is complete, each piece moves through a series of steps to add precise functionality. We employ over 20 computer numeric controls (CNC) machines to ensure that the hardware functions flawlessly for a lifetime. These state-of- the-art computer programs are written to make our machines perform to our exacting specifications. We also have large lathes to turn specific parts, as well as water-jet machines to cut 2D custom parts using high pressure. FINISHING TOUCHES Once in the finishing facility, the artistry and detail of the pieces are highlighted with a warm, hand-applied patina and hand-rubbed polish. The finish grows richer and deeper over time as it responds to its environment for one-of-a-kind character. The end product is a sculptural work of art, the handiwork of many, and one that is expertly crafted to last a lifetime.