To achieve D’Clark’s intricate vision, models for the sculptures were created using 3D scanning of live subjects. Deep facial dimpling and undercutting, designed for a tactile experience, posed significant technical challenges for the Foundry experts. Traditional sand patterns would have chemically bonded to the complex shapes, making the process prohibitively expensive and nearly impossible to execute. 

 

Maybrey Precision Castings solved this challenge by pioneering the use of 3D-printed sand moulds, enabling precise and cost-effective production. The sculptures were cast in 52 segments, using Silicon Bronze for its exceptional weldability and ability to accommodate variations in wall thickness. 

 

A bespoke running system designed by the team at Maybrey ensured optimal metal flow, incorporating double pours and multiple ingates to prevent blemishes from oxides and gas pockets. The sculptures were then polished, assembled, and welded by Millimetre, an award-winning design and fabrication firm in West Sussex, before being shipped to Alabama for installation.