The Traditional way

When man first discovered fire in the form of a forest fire, little did he know then that he could produce, use and misuse the same feared power in the future that was to soon follow. Likewise, little did he know that the stones he used as his facilitating object was to be massively replaced by metals, which were comparatively malleable and ductile and could be changed in form when heated and with other such boons of metals which was otherwise not offered by the crude stone objects. It was perhaps after the discovery of these metals that man increasingly refined their senses and developed their tastes in shapes and figures of objects which was to later give birth to a different profession altogether called metalwork or metal casting. Little was it known then that this very profession was to employ a whole lot of people with refined tastes and senses that would help them to work continuously for nights and days with a sense of satisfaction that is next to inexplicable.

It took approximately 6000 years for the culmination of present-day use of metals on its way of development. Experts believe that the Metal Industry in Nepal has existed for more than 2000 years. However the first recorded evidence of Copper and Bronze objects being produced in Nepal can e traced back to the early Lichhavi period (500-880 A.D.). Statues dating from the 6th century were casted at Chandeshwari temple in Banepa and at Shanku. Most experts assume Patan to be the city where the art of metal casting originated, flourished and clustered. Golden Temple or “Kwa bahal” built in the fourteenth century is standing evidence to its origin. Records dating back to mid-1500s also describe the flourishing metal industry in a section of Patan. Probably the availability of copper deposits in this area accelerated the flourishing of the industry. Until this day the city of patan beats and thrives with the metal casting industry, which has become a lifeline of sorts to these people. This city, which is the manufacturing core of statues cast in metal sculptures, exports its products to the world outside apart from serving the indigenous market. In order to save this traditional from of art, the government has opened up Patan Industrial Estate where metal casting is one of the industries among the other Handicraft industries. The Newars of the valley, renowned for ages comprise the majority of skilled and preferred artisans.

The metals are casted using a very primitive method of metal casting known as the lost wax method and the metals used for the purpose are bronze, brasss and copper. Bronze is an alloy of 75% copper and 25% tin. Bronze, which is relatively more expensive than copper is also known as ‘kasa’. Like Bronze, brass or ‘pittal’ is an alloy with 75% copper and 25% zinc. The lost-wax method, which was introduced by the Egyptians during the Bronze Age, is known today as the investment method of casting. This process is also known as the precision-casting process.

In this method an exact model or pattern of the article to be cast is made in wax from the original piece known as the masterpiece which is at all times a metallic piece shaped to exact dimensions. This first and shapely wax impression serves as a masterpiece or model to other wax pieces in return and is locally known as ‘maina’ and is made from the combination of bee-wax and incense powder of Sal wood. Several of these pieces are derived from the original one depending on the demand and supply graph. they are then covered with a claylike material to form the mould. Thereafter they are plastered wholly with a paste that is a combination of cow dung and mud. The same ‘maina’ is further wrapped up with a paste that is a mixture of cow-dung, rice chaff and mud. Depending on the size of these pieces, these mixtures are applied on to them. Usually the mixture is applied in two layers and it covers the unreachable corners too. However the bigger ‘mainas’ need at least 5 coatings. Thereafter, these dices are left to dry in the sun. It is to be reminded here that this process is not used in the monsoons for the dried in the sun. However some of the craftsmen do continue with the process in room temperature thereby taking more days for plastered ‘maina’ to dry up.

The following process requires the composite to be heated. The heating hardens the mould and simultaneously melts the wax, which drains off through the tiny hole kept for the very purpose, leaving an exact negative impression, which is then filled with molten metal and allowed to solidify. Simultaneously the red-hot hollow piece is heated in the oven made of brick and mud plaster prior to the filling process. Once the molten metal is filled, the object is left to cool in the nearby area. As the metal inside the mould is cooled, the outside cover is broken and the metal parts that have taken shape inside are taken out. The outcome is the shapely parts of metal pieces that were to later make up the beautiful figures of some Hindu or Buddhist dieties viz., Tara, Buddha, Bodhisatvas and Lokeshwar.

This process inadvertently produces castings having greater dimensional accuracy and relatively smoother surfaces as compared to other methods of metal casting. These accomplished products of casted metals are further made smoother and brilliantly shining with the use of as and paper and other razor like instruments that give it a proper shape and perfect shine. Designs are also engraved on these metal pieces. These pieces of metals are etched separately for engraving designs.

These beautiful metallic parts are later united or brought together by gas welding and by using copper nails. Only brass statues are coloured with boot polish, which is quite an outdated practice but still very effective. Both brown and black coloured boot polish are used. bronze is used only for making bells especially the bells used for ringing and not used as a showpiece.

The Nepalese statue of Krishna gilded in Bronze with turquoise and gems belonging to the 18th century proudly stands in the Prince of Wales Museum of Western India in Mumbai. Though the statue is not so much of an antique, it has undoubtedly found a place in one of the finest museums of the world as a model in fine metal casting and has even found its way into the encyclopedia. These facts make it evident that Metal casting in Nepal is indeed an ancient practice and a very skilled one-one to reckon with.