Ceramic shell materials for the lost wax method Everything for the ceramic shell process in one place: binders, flour and stucco, additives, and complete sets. From fine fused silica to zircon, for both precision and art foundries. Whether you cast bronze or aluminum, here you will find the materials and...
Ceramic shell materials for the lost wax method (12)
Ceramic shell materials for the lost wax method
Everything for the ceramic shell process in one place: binders, flour and stucco, additives, and complete sets. From fine fused silica to zircon, for both precision and art foundries. Whether you cast bronze or aluminum, here you will find the materials and guidance to build a reliable, refractory shell.
The ceramic shell method is a lost wax method where a hard, heat-resistant shell is built up layer by layer around a wax model. The wax is burned out, the model is lost (hence the name), and the remaining shell forms a mold into which metal is cast.
Choose a category
Looking for something specific? Go directly to the right product group.
Binders
The binder you use to create your own slurry. Water-based, ready to mix with flour.
Stucco & flour
Fused silica, aluminum silicate, and zircon, in flour and sand fractions for each layer of the shell.
Additives
Defoamer, wetting agent, drying indicator, and suspension powder to fine-tune your slurry.
Complete sets & ready-to-use
Ready-to-start combinations and pre-mixed slurries. Get started immediately without creating your own recipe.
Advantages of the ceramic shell
- ✓Fast burnout — the shell is burned out in approximately 2 hours, saving a lot of energy compared to plaster and chamotte molds.
- ✓Lighter weight — the shell is significantly lighter than a plaster or chamotte mold and therefore easier to handle.
- ✓Consistent quality — a smooth, porous shell provides better and more uniform casting quality, with less finishing work.
- ✓Accessible process — manageable, even for those who use the method occasionally.
The ceramic shell process in brief
You make a slurry from a binder liquid and a fine flour, and also use a coarser stucco material. By repeatedly dipping the wax model into the slurry and then stuccoing it, you build up a multi-layer shell in a few hours to days. On average, this involves 6 to 12 layers; the total process usually takes 3 to 6 days.
For sporadic use, the method is quite manageable. If you want to work with it structurally, it pays to set up a fixed process. We are happy to help you with materials, advice, and clear manuals.
Four ways to prepare your slurry
The main difference between the options is how the slurry stays in suspension: continuous mixing, supplied ready-to-use, or self-prepared with a suspension aid.
Option 1 · Traditional 24/7 slurry
The original method and most commonly used in larger foundries. You make your own slurry by mixing a binder (a water-based silica and polymer suspension) with flour. Optionally, you can add a drying indicator. Please note: our binder already contains wetting agent, defoamer, and polymer, so you usually don't need to purchase these separately.
Advantage: the individual components are shelf-stable for years when unmixed, and you have complete control over the composition.
Disadvantage: after mixing, the slurry must be kept in continuous motion. If it stands still for too long, it will gel and thicken, becoming unusable. Therefore, you need a mixing machine that runs year-round, which is often impractical for smaller users.
Option 2 · Ready-to-use slurry (Jus-Dip)
A convenient variant where the manufacturer has already prepared the slurry for you from binder and flour. Moreover, it does not need continuous stirring, only before use and once a week. The slurry contains all components: binder, flour, wetting agent, defoamer, a suspending agent, and a drying indicator.
Advantage: ready for immediate use and no continuous stirring required.
Disadvantage: you have no control over which flour was used (you can adjust the fluidity yourself), and the shelf life is usually a maximum of one year.
Option 3 · Self-prepared with Shellspen
A hybrid approach: you make your own slurry as in option 1, but add a third component, the Shellspen suspension powder. This eliminates the need for continuous stirring. This way, you combine the control and shelf life of option 1 with the convenience of option 2.
Advantage: full control over the slurry, long shelf life of individual components, and no continuous mixing.
Disadvantage: the Shellspen powder must be carefully and evenly mixed. When using part of a bag, the powder must first be thoroughly homogenized.
Our recommendation
Option 4 · Self-prepared with xanthan
Our newest and favorite hybrid. Here too, you make your own slurry as in option 1, but you use a small amount of xanthan gum to keep the flour in suspension. The result is a reliable, periodically mixed slurry with the same advantages as option 3, but with a simpler and more economical suspension aid.
Xanthan is widely available (online, in supermarkets, and at baking and pastry supply stores), and you only need a small amount of it. The binder and flour, as with the other options, you can obtain from us.
Advantage: full control, long shelf life of components, no continuous mixing, and a low barrier to entry because the suspension aid is inexpensive and widely available.
Good to know: this formulation uses a finer flour (325 mesh) and a different ratio compared to the classic slurry. The manual below describes everything step by step.
For all hybrid and ready-to-use options: also read the manual for option 1, so you know how to maintain and adjust a slurry.
Manuals and documentation
The manuals below will help you get started. If you want a different composition or a larger order, please feel free to contact us.
- → Option 1 — Traditional 24/7 slurry: Ceramic shell method manual (PDF)
- → Option 2 — Ready-to-use slurry: Jus-Dip product information (PDF)
- → Option 3 — Self-prepared with Shellspen: Manual for periodically mixed slurry based on Shellspen (PDF)
- → Option 4 — Self-prepared with xanthan: Manual for periodically mixed slurry based on xanthan (PDF) RECOMMENDED
Keep a slurry logbook
We strongly recommend keeping a logbook of your slurry's quality and the adjustments you make. This way, over time, you will understand exactly how to achieve a desired result. Examples:
💡 Tip: Eric W. Stephenson's YouTube channel clearly explains the various steps of the lost wax process with the ceramic shell. Check out LunarburnStudio.