Bronze foundry art returns to the Big Horn Basin in Frannie

Emma Scott, 23 years old, had aspirations of becoming a welder and was given the opportunity several years ago at Caleco Foundry, a third-generation bronze casting business in Cody. While working there she fell in love with another metalworking occupation and began training under her colleagues to become a bronze founder. But when the foundry burned to the ground earlier this year, Scott knew she wanted to keep bronze art in the Big Horn Basin.

Empress Bronze Foundry is a “small backyard foundry” recently established in Frannie by Scott.

“I wanted to bring it (bronze art) to a small community,” she said.

Scott said the town of Frannie has been very supportive, and she’s received lots of help from various local residents. The foundry’s first pour, commemorating the official opening of the business, just occurred on October 30. The roar of her kiln and furnace have now become a recognized noise throughout the town.

“It’s hard to believe that just four months ago even this concrete pad wasn’t here,” Scott said, standing amidst the large equipment she’s acquired, necessary for the investment casting process.

Currently, Empress Bronze Foundry specializes in Western art, but Scott noted they would like to expand their horizons in the future. Artists specializing in bronze will bring their sculptures, usually made out of clay, plaster or other materials, to the foundry.

Scott uses the “lost wax process” to turn the artist’s sculpture into a bronze masterpiece. This technique has been used since 3000 BC and is still a widely used method of metal casting today.  The artist’s sculpture will be made into a wax model, which is covered with a clay-like substance. This coated model is called the “investment mold.” Scott will then take the investment mold and place it into a large kiln at 1800 degrees Fahrenheit for 30 minutes. Flames leap out of the kiln as the wax inside the models melts away. This step, Scott said, is what made her fall in love with bronze casting. 

Empress Bronze Foundry has another mastermind behind the scenes. Kyle Bogan, also a former employee of Caleco Foundry, assists throughout the process and is the “head of operations,” according to Scott. Bogan is from Cody and has been in this field for more than 10 years.

“I love it,” Bogan said. “It’s like a big science project.”

Once the wax has been melted from the investment mold, leaving behind an empty cavity, the molds are carefully removed from the kiln. Each mold is then meticulously inspected for cracks and placed upside down in a large receptacle of sand.

Meanwhile, the molten bronze inside the furnace is checked for temperature. Bronze has a melting point of 1,675 degrees Fahrenheit, but founders are looking for temperatures around 2,300^o Fahrenheit.

“We like it hot. That makes for cleaner casts,” Scott explained. 

Once the desired temperature is reached, the glowing orange molten bronze is then quickly poured into each hollow investment mold. As the metal cools, you can hear the “music” of it cooling through a variety of crackle and pop sounds. When the metal has returned to a solid state, Scott and Bogan will break the molds and use a sandblaster to buff the completed bronze statue.

Scott and Bogan both credit their time employed at Caleco Foundry for their unique skills and talent in bronze casting. In honor of their former place of employment, they are planning a “winter solstice pour” on December 21, a long-time tradition at the former Cody foundry. They will be inviting the public to come learn about their process and tour the newly opened foundry in Frannie. The highlight of the evening will be a night-time bronze pour with the glowing molten metal as the star of the show. More details will be posted on their Facebook page.

Currently, Empress Bronze Foundry work is arranged by appointment only. Find them on Facebook to contact Scott.