D’source 1

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Design Resource
Chola Bronze Casting -
Swamimalai, Tamilnadu
Metal Icons

by
Prof. Bibhudutta Baral and Hariharasudan T
NID, Bengaluru

Source:
http://www.dsource.in/resource/chola-bronze-cast-
ing-swamimalai-tamilnadu

1. Introduction
2. Tools and Raw Materials
3. Making Process
4. Products
5. Contact Details
D’source 2
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Design Resource Introduction

Chola Bronze Casting -
Swamimalai, Tamilnadu The Chola dynasty was the dominant cultural, artistic, religious and political force in south India, for a period of
Metal Icons four hundred years from the ninth to thirteenth century. Its dynasty extended till Sri Lanka and nearby Maldives
islands, maintained regular contact with Java, Myanmar, Malaysia and china. Enlightened patrons of the arts,
by Chola rulers commissioned elegant sculptures and dedicated majestic temples to Hindu deities in order to pro-
Prof. Bibhudutta Baral and Hariharasudan T claim the power, wealth, and piety of Chola dynasty. During this golden age, the arts music and dance, poetry and
NID, Bengaluru drama, architecture and sculpture flourished.

Rajaraja Chola, born as Arunmozhivarman was one of the greatest kings born to Parantaka chola II and Vanavan
Mahadevi. He was a Valiant warrior and a master strategist who built his empire by his might of his army, navy
Source: and political treaties. Rajaraja built the Great Temple of Thanjavur. It is a magnificent haven of architecture, sculp-
http://www.dsource.in/resource/chola-bronze-cast- ture and paintings. During the construction of temple Rajaraja brought carpenters, sculptors, goldsmiths, stone
ing-swamimalai-tamilnadu/introduction masons and other artists from places all around to build the temple. After the construction of the temple these
people settled down in and around Thanjavur. Swami Malai is one such place.

Swami Malai is a panchayat town near Kumbakonam in Thanjavur District. It lies on the banks of river Kaveri
1. Introduction and is one of the six abodes of the Lord Muruga. One group of artists called as “Sthapati” settled in this region.
2. Tools and Raw Materials Sthapati means an architect or master carpenter or builder. These people after settling down in Swamimalai
3. Making Process started making bronze icons. Since the time of Rajaraja chola these sthapati are producing bronze icons which
4. Products are spread all around the world.

5. Contact Details Sthapati’s comes under vishwakarma community. The designers and artists of the classical Indian traditions
of sculpture (stone and metal) and architecture were known as the Vishwakarma community, whose name is
mentioned in the ancient Vedas and the Puranas. In south India, the Vishwakarma community of artisans is also
known as the Kammalas.

During the Thanjavur temple construction time Sthapati’s emerged a distinct class of craftsmen. They are not
merely stone carvers or metal workers but something more.” Their familiarity with the Shilpa Shastras, the
complex nature of metal icon production, and other religious traditions related to their craft has elevated them
beyond the rank of ordinary craftsmen.

The Sthapathi community in Swamimalai who trace their descent back to an ancestor named Agora Veerapathira
Sthapathy from the time of the temple construction are residing in that region. Around three hundred families
are presently into bronze casting business.
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Design Resource One such family is presently staying in Swami Malai Sri S. Devasenapathy Sthapathy and sons. Mr. Devasenpathy
Chola Bronze Casting - sthapathy is a National award winner and is the founder of Sri Jayam.

Swamimalai, Tamilnadu
Metal Icons

by
Prof. Bibhudutta Baral and Hariharasudan T
NID, Bengaluru

Source:
http://www.dsource.in/resource/chola-bronze-cast-
ing-swamimalai-tamilnadu/introduction

1. Introduction
2. Tools and Raw Materials
Entrance of Sri Jayam Industries where traditional chola Radhakrishnan stapathy, srikandan sthapathy, Swami-
3. Making Process bronze icons are made. nathan sthapathy, (three brothers) senior artists at Sri
4. Products Jayam Industries
5. Contact Details
D’source 4
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Design Resource
Chola Bronze Casting -
Swamimalai, Tamilnadu
Metal Icons

by
Prof. Bibhudutta Baral and Hariharasudan T
NID, Bengaluru

Source:
http://www.dsource.in/resource/chola-bronze-cast-
ing-swamimalai-tamilnadu/introduction
Some of the award received by artisans. National award is presented to S.Devasenapathy Stapa-
thy (Artisan father).
1. Introduction
2. Tools and Raw Materials
3. Making Process
4. Products
5. Contact Details

A beautiful Ganesa idol is made for worship. Artisan D. Radhakrishna sthapathy working on wax
mold of Lord Nataraja.
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Design Resource
Chola Bronze Casting -
Swamimalai, Tamilnadu
Metal Icons

by
Prof. Bibhudutta Baral and Hariharasudan T
NID, Bengaluru

Source:
http://www.dsource.in/resource/chola-bronze-cast-
ing-swamimalai-tamilnadu/introduction
Unwanted and shard surface have been removed using Bronze statue of a swamiji.
the chisel.
1. Introduction
2. Tools and Raw Materials
3. Making Process
4. Products
5. Contact Details

Cement mold of a buddha, for making wax model.

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Design Resource Tools and Materials

Chola Bronze Casting -
Swamimalai, Tamilnadu Following are the tools and raw materials required for Bronze Casting:
Metal Icons
• Leaf Strip: The measurements of the statute is measured using the leaf strip.
by
Prof. Bibhudutta Baral and Hariharasudan T • Spatula: It is used to smoothen and shaping the wax model.
NID, Bengaluru
• Knife: It is used to the remove unwanted portions of the wax model.

• Scrapper: It is used to impart sharper relief on the wax model.

Source:
http://www.dsource.in/resource/chola-bronze-cast- • Foot Rule: It is used for measuring purpose.
ing-swamimalai-tamilnadu/tools-and-raw-materials
• Soldering Iron: It is used to even out the edges on the wax model and it is usually an iron rod with handle and is
heated using fire.
1. Introduction • Hammer: It is used to chisel the statue, it is of various sizes.
2. Tools and Raw Materials
3. Making Process • Chisel: It is used along with hammer to remove the unwanted metal from casting.
4. Products
• Engraving Tool: These are similar to chisel but used to carve out fine details.
5. Contact Details
• Files: It is used to remove the sharp edges on the casting.

• Forceps: It is used to handle the hot crucibles during casting.

• Air Blower /Furnace: It is used to blow air in order to build up the fire inside the furnace.

• Crucible: It is used to melt the metals for casting.

• Kettle: It is used to melt the wax, used for pouring into the mold.

• Tongs: Both long and small are used to handle different size crucibles.

• Crucible Ladles: For Skimming the surface of hot crucible of slag and unwanted material.
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Design Resource • Wax: It is used in making models of the statue.

Chola Bronze Casting -
Swamimalai, Tamilnadu
Metal Icons

by
Prof. Bibhudutta Baral and Hariharasudan T
NID, Bengaluru

Source:
http://www.dsource.in/resource/chola-bronze-cast-
ing-swamimalai-tamilnadu/tools-and-raw-materials

1. Introduction Different type of chisels used for finishing works. Burner used for heat the sheet metal.
2. Tools and Raw Materials
3. Making Process
4. Products
5. Contact Details

Crucible used to melt the metal. Pencil, compass, Scale etcetera used for various mark-
ing.
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Design Resource
Chola Bronze Casting -
Swamimalai, Tamilnadu
Metal Icons

by
Prof. Bibhudutta Baral and Hariharasudan T
NID, Bengaluru

Source:
http://www.dsource.in/resource/chola-bronze-cast-
ing-swamimalai-tamilnadu/tools-and-raw-materials
Wax material, used in making bronze statue. Metal polish, used to polishing the final product.

1. Introduction
2. Tools and Raw Materials
3. Making Process
4. Products
5. Contact Details

A brush used in cleaning the casting after removing The hammer used for various operations during casting
from the mold. like breaking of mold, chiseling etc.
D’source 9
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Design Resource
Chola Bronze Casting -
Swamimalai, Tamilnadu
Metal Icons

by
Prof. Bibhudutta Baral and Hariharasudan T
NID, Bengaluru

Source:
http://www.dsource.in/resource/chola-bronze-cast-
ing-swamimalai-tamilnadu/tools-and-raw-materials
Different type of file used during finishing operation. Handsaw used for cutting the raw material.

1. Introduction
2. Tools and Raw Materials
3. Making Process
4. Products
5. Contact Details

Scrap metal used for casting.

D’source 10
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Design Resource Making Process

Chola Bronze Casting -
Swamimalai, Tamilnadu • The casting process starts by preparation of the wax model of the statue.
Metal Icons
• The overall structure, size and figure of statue is arrived based on the Agama Shastra.
by
Prof. Bibhudutta Baral and Hariharasudan T • Measurements are noted using a narrow ribbon of coconut tree leaf cut to the length of the model and folded
NID, Bengaluru to different lengths in proportion to the length of various parts of the model.

• Wax is a mixture of bee wax with resin and ground nut oil.

Source: • After the wax model is dried, the fine loam or alluvial soil is applied around the model for thickness of approxi-
http://www.dsource.in/resource/chola-bronze-cast- mately 2.5-3cms, depending on the size of the statue and allowed to dry naturally.
ing-swamimalai-tamilnadu/making-process
• Orifices are made on the mold for pouring the molten metal and draining of the molten wax and gases formed
during casting.
1. Introduction • After drying another layer of mixture of clay and sand is applied, and naturally allowed to dry in the sun light
2. Tools and Raw Materials 2-3 days.
3. Making Process
3.1. Stand • Once it is dried, the mold is reinforced using a metal wires in order to avoid breakage.

3.2. Statue • The dried mold is set on fire for melting the wax inside and the molten wax is collected using a vessel, which
4. Products can be reused, during this 50% of wax is lost. During earlier days the wax used was not collected and it used to
5. Contact Details evaporate as fumes and gases, so the name Lost wax method.

• Simultaneously the raw metal or alloys are weighed, according to the quantity required for casting and filled in
crucibles. For bronze the ratio of copper, brass and lead are 29:2:1 Crucibles are made of special type of mud to
withstand very high temperature.

• The ratio of weight of wax and alloy required to cast the product is in the ratio of 1:8 which means if the wax
model weighs 1 kg then the casting will weigh around 8kg.

• Crucibles are filled with the required quantity of the metal and placed in the furnace for melting.
D’source 11
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Design Resource • Looking at the color of the flame in the fire vent craftsmen can easily identify whether the raw metal is molten
Chola Bronze Casting - are not.

Swamimalai, Tamilnadu • The normal flame is reddish yellow but the flame coming out from the molten metal is distinctively greenish
Metal Icons blue in color.

by • After the molten wax is completely drained, the mold is moved to a new pit which is made to accommodate the
Prof. Bibhudutta Baral and Hariharasudan T mold for casting.
NID, Bengaluru
• The crucible is removed from the furnace and molten metal is poured into the mold through the holes provided.

• Molten metal is poured into the mold while the mold is still hot in order to avoid sudden cooling and breakage
Source: of the casting.
http://www.dsource.in/resource/chola-bronze-cast-
ing-swamimalai-tamilnadu/making-process • The casting is allowed to cool & set for 12-24 hours and mold is removed from the pit and casting is taken out of
the mold.

• The casting obtained is unfinished and further processing is required.

1. Introduction
2. Tools and Raw Materials • The contours and details of the original wax pattern are recaptured by smoothing the uneven surfaces and then
3. Making Process by chiseling.
3.1. Stand
• The details of dress and ornaments as well as other final touches are engraved into the statue.
3.2. Statue
4. Products • The surface of the statue is smoothened by rubbing it with fine-grade emery paper.
5. Contact Details
• Finally, the piece is polished and packed.
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Design Resource
Chola Bronze Casting -
Swamimalai, Tamilnadu
Metal Icons

by
Prof. Bibhudutta Baral and Hariharasudan T
NID, Bengaluru

Source:
http://www.dsource.in/resource/chola-bronze-cast-
ing-swamimalai-tamilnadu/making-process

1. Introduction
2. Tools and Raw Materials
3. Making Process
3.1. Stand
3.2. Statue
4. Products
5. Contact Details
D’source 13
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Design Resource
Chola Bronze Casting -
Swamimalai, Tamilnadu
Metal Icons

by
Prof. Bibhudutta Baral and Hariharasudan T Stand Statue
NID, Bengaluru

Source:
http://www.dsource.in/resource/chola-bronze-cast-
ing-swamimalai-tamilnadu/making-process

1. Introduction
2. Tools and Raw Materials
3. Making Process
3.1. Stand
3.2. Statue
4. Products
5. Contact Details
D’source 14
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Design Resource Stand

Chola Bronze Casting -
Swamimalai, Tamilnadu
Metal Icons

by
Prof. Bibhudutta Baral and Hariharasudan T
NID, Bengaluru

Source:
http://www.dsource.in/resource/chola-bronze-cast-
ing-swamimalai-tamilnadu/making-process/stand

1. Introduction
2. Tools and Raw Materials Artisan applying soap powder on the mold before cast- Artisan is assembling the mold for making wax model of
3. Making Process ing. the pedestal.
3.1. Stand
3.2. Statue
4. Products
5. Contact Details
D’source 15
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Design Resource
Chola Bronze Casting -
Swamimalai, Tamilnadu
Metal Icons

by
Prof. Bibhudutta Baral and Hariharasudan T
NID, Bengaluru

Source:
http://www.dsource.in/resource/chola-bronze-cast-
ing-swamimalai-tamilnadu/making-process/stand
Wax is being melt. Molten wax is poured into the mold.

1. Introduction
2. Tools and Raw Materials
3. Making Process
3.1. Stand
3.2. Statue
4. Products
5. Contact Details

After the wax gets solidified, the mold is being removed. Wax mold is being removed from the mold.
D’source 16
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Design Resource
Chola Bronze Casting -
Swamimalai, Tamilnadu
Metal Icons

by
Prof. Bibhudutta Baral and Hariharasudan T
NID, Bengaluru

Source:
http://www.dsource.in/resource/chola-bronze-cast-
ing-swamimalai-tamilnadu/making-process/stand
The wax mold is being finished before assemble. Fully assembled wax mold.

1. Introduction
2. Tools and Raw Materials
3. Making Process
3.1. Stand
3.2. Statue
4. Products
5. Contact Details

Runner for the mold is being made for the molten wax The finished molds are kept for Sun drying.
to flow out.
D’source 17
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Design Resource
Chola Bronze Casting -
Swamimalai, Tamilnadu
Metal Icons

by
Prof. Bibhudutta Baral and Hariharasudan T
NID, Bengaluru

Source:
http://www.dsource.in/resource/chola-bronze-cast-
ing-swamimalai-tamilnadu/making-process/stand
The Molds are being tied with iron wires to avoid cracks The mold is heated in order to remove the wax.
during heating.
1. Introduction
2. Tools and Raw Materials
3. Making Process
3.1. Stand
3.2. Statue
4. Products
5. Contact Details

The final layer of clay is applied to hold the wire and The mold is getting arranged for pre heating.
mold tightly before preheating.
D’source 18
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Design Resource
Chola Bronze Casting -
Swamimalai, Tamilnadu
Metal Icons

by
Prof. Bibhudutta Baral and Hariharasudan T
NID, Bengaluru

Source:
http://www.dsource.in/resource/chola-bronze-cast-
ing-swamimalai-tamilnadu/making-process/stand
Artisan placing the mold in the pit for casting. Molten metal is poured into the mold.

1. Introduction
2. Tools and Raw Materials
3. Making Process
3.1. Stand
3.2. Statue
4. Products
5. Contact Details

The mold is allowed to cool. Mold is broken using hammer to remove the casting.
D’source 19
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Design Resource
Chola Bronze Casting -
Swamimalai, Tamilnadu
Metal Icons

by
Prof. Bibhudutta Baral and Hariharasudan T
NID, Bengaluru

Source:
http://www.dsource.in/resource/chola-bronze-cast-
ing-swamimalai-tamilnadu/making-process/stand
Sharp and unwanted surface are being chiseled. Finally, the product is polished using metal polish.

1. Introduction
2. Tools and Raw Materials
3. Making Process
3.1. Stand
3.2. Statue
4. Products
5. Contact Details
D’source 20
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Design Resource Statue

Chola Bronze Casting -
Swamimalai, Tamilnadu
Metal Icons

by
Prof. Bibhudutta Baral and Hariharasudan T
NID, Bengaluru

Source:
http://www.dsource.in/resource/chola-bronze-cast-
ing-swamimalai-tamilnadu/making-process/statue

1. Introduction
2. Tools and Raw Materials Artisan is sculpting the basic structure of the body All body parts are made individually.
3. Making Process using wax.
3.1. Stand
3.2. Statue
4. Products
5. Contact Details
D’source 21
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Design Resource
Chola Bronze Casting -
Swamimalai, Tamilnadu
Metal Icons

by
Prof. Bibhudutta Baral and Hariharasudan T
NID, Bengaluru

Source:
http://www.dsource.in/resource/chola-bronze-cast-
ing-swamimalai-tamilnadu/making-process/statue
All the individual parts are joined to make a complete Wax models are kept in water to avoid any distortion.
wax model.
1. Introduction
2. Tools and Raw Materials
3. Making Process
3.1. Stand
3.2. Statue
4. Products
5. Contact Details

Artisan applying clay on the wax model. One side of wax model is cover using clay and allowed
for sun drying.
D’source 22
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Design Resource
Chola Bronze Casting -
Swamimalai, Tamilnadu
Metal Icons

by
Prof. Bibhudutta Baral and Hariharasudan T
NID, Bengaluru

Source:
http://www.dsource.in/resource/chola-bronze-cast-
ing-swamimalai-tamilnadu/making-process/statue
Product show is model half covered with clay. The completely covered wax model with clay and sun
dried.
1. Introduction
2. Tools and Raw Materials
3. Making Process
3.1. Stand
3.2. Statue
4. Products
5. Contact Details

Molds are tied using iron wires to avoid cracks. The molds are ready for heating.
D’source 23
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Design Resource
Chola Bronze Casting -
Swamimalai, Tamilnadu
Metal Icons

by
Prof. Bibhudutta Baral and Hariharasudan T
NID, Bengaluru

Source:
http://www.dsource.in/resource/chola-bronze-cast-
ing-swamimalai-tamilnadu/making-process/statue
Furnace is being arrange for collecting molds and wax. Molten wax is flowing out of the molds during heating.

1. Introduction
2. Tools and Raw Materials
3. Making Process
3.1. Stand
3.2. Statue
4. Products
5. Contact Details

Artisan is removing the mold from the furnace. After removing from the furnace, another layer of clay
is being applied.
D’source 24
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Design Resource
Chola Bronze Casting -
Swamimalai, Tamilnadu
Metal Icons

by
Prof. Bibhudutta Baral and Hariharasudan T
NID, Bengaluru

Source:
http://www.dsource.in/resource/chola-bronze-cast-
ing-swamimalai-tamilnadu/making-process/statue
The mold is getting arrange in the furnace for pre heat- Artisan is placing the mold in the pit in order to prevent
ing. from cracking while pouring molten metal.
1. Introduction
2. Tools and Raw Materials
3. Making Process
3.1. Stand
3.2. Statue
4. Products
5. Contact Details

Furnaces is being prepared for melting the metal. Crucible is placed inside the furnace and covered with
coal all around.
D’source 25
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Design Resource
Chola Bronze Casting -
Swamimalai, Tamilnadu
Metal Icons

by
Prof. Bibhudutta Baral and Hariharasudan T
NID, Bengaluru

Source:
http://www.dsource.in/resource/chola-bronze-cast-
ing-swamimalai-tamilnadu/making-process/statue
Metal is getting melted in the Furnace. Crucible is removed from furnace using the tongs.

1. Introduction
2. Tools and Raw Materials
3. Making Process
3.1. Stand
3.2. Statue
4. Products
5. Contact Details

Molten metal is being poured into the mold. Molds are kept out for cooling.
D’source 26
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Design Resource
Chola Bronze Casting -
Swamimalai, Tamilnadu
Metal Icons

by
Prof. Bibhudutta Baral and Hariharasudan T
NID, Bengaluru

Source:
http://www.dsource.in/resource/chola-bronze-cast-
ing-swamimalai-tamilnadu/making-process/statue
Molds is being brokened to remove the casting. Casting obtained is cleaned using chisel and brush.

1. Introduction
2. Tools and Raw Materials
3. Making Process
3.1. Stand
3.2. Statue
4. Products
5. Contact Details

Sharp and unwanted surface are being chiseled. Artisan is scraping the surface to give the smooth finish.
D’source 27
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Design Resource
Chola Bronze Casting -
Swamimalai, Tamilnadu
Metal Icons

by
Prof. Bibhudutta Baral and Hariharasudan T
NID, Bengaluru

Source:
http://www.dsource.in/resource/chola-bronze-cast-
ing-swamimalai-tamilnadu/making-process/statue

1. Introduction A final product of bronze statue by artisan.

2. Tools and Raw Materials
3. Making Process
3.1. Stand
3.2. Statue
4. Products
5. Contact Details
D’source 28
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Design Resource Products

Chola Bronze Casting -
Swamimalai, Tamilnadu Various icons like of Lord Shiva and Parvathi and god and goddess are made.
Metal Icons
List of few icons made for international customer,
by
Prof. Bibhudutta Baral and Hariharasudan T • Sri Muthu Mariayamman at Sri Muthu Mariyamman temple, Upper Tooting road, Tooting – London
NID, Bengaluru
• Sri Kaliyamman at Sri Kaliyamman Temple, Reunion, Mauritius

• Sri Yoga Narasimmar at Sri Perumal Temple, Sirangoon Road, Singapore

Source:
http://www.dsource.in/resource/chola-bronze-cast- • Sri Sudarshana Moorthy at Sri Perumal Temple, Sirangoon Road, Singapore
ing-swamimalai-tamilnadu/products
• Sri Iyyappan at Sri Ragavendra Swamy Peedam, Johore, Malaysia

• Sri Natarajar supplied to World Peace Centre Pune, installed in the Head Quarters of United National Education-
1. Introduction al Scientific and Cultural Organization at Paris.
2. Tools and Raw Materials
3. Making Process • Sri Balaraman , Sri Uduppi Krishna, Sri Krishnan, Sri Radha, Six Main Deity Of Iskcon, 21 Feet Kalasam, Temple
Bangalore.
4. Products
5. Contact Details • Sri Natarajar Thandavam 108 poses

• Sri Ardhanareeswarar.

Apart from the Divine icons, public installation statues are also being made..
D’source 29
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Design Resource
Chola Bronze Casting -
Swamimalai, Tamilnadu
Metal Icons

by
Prof. Bibhudutta Baral and Hariharasudan T
NID, Bengaluru

Source:
http://www.dsource.in/resource/chola-bronze-cast-
ing-swamimalai-tamilnadu/products
Furnace is being arrange for collecting molds and wax. Molten wax is flowing out of the molds during heating.

1. Introduction
2. Tools and Raw Materials
3. Making Process
4. Products
5. Contact Details

Artisan is removing the mold from the furnace. After removing from the furnace, another layer of clay
is being applied.
D’source 30
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Design Resource
Chola Bronze Casting -
Swamimalai, Tamilnadu
Metal Icons

by
Prof. Bibhudutta Baral and Hariharasudan T
NID, Bengaluru

Source:
http://www.dsource.in/resource/chola-bronze-cast-
ing-swamimalai-tamilnadu/products

1. Introduction
2. Tools and Raw Materials
3. Making Process
4. Products
5. Contact Details Furnace is being arrange for collecting molds and wax.
D’source 31
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Design Resource Contact Details

Chola Bronze Casting -
Swamimalai, Tamilnadu This documentation was done by Professor Bibhudutta Baral and Hariharasudan T. at NID, Bengaluru.
Metal Icons
You can get in touch with him at bibhudutta[at]nid.edu
by
Prof. Bibhudutta Baral and Hariharasudan T You could write to the following address regarding suggestions and clarifications:
NID, Bengaluru
Key Contacts:
Shri.Jayam Industries
Swamimalai
Source: Tamilnadu
http://www.dsource.in/resource/chola-bronze-cast- Landphone: 0435-2454424
ing-swamimalai-tamilnadu/contact-details

Helpdesk Details:
Co-ordinator
1. Introduction Project e-kalpa
2. Tools and Raw Materials R & D Campus
3. Making Process National Institute of Design
4. Products #12 HMT Link Road, Off Tumkur Road
Bengaluru 560 022
5. Contact Details India

Phone: +91 80 2357 9054

Fax: +91 80 23373086
Email: dsource.in[at]gmail.com