Order Placement Our process begins with the receipt of your order. Your order includes all of the necessary components of your bronze plaque (size, design, inscription, emblems, etc.). After your order is received and confirmed, we develop a scaled paper representation of the information provided. This representation, called a proof, is sent to you for your approval before we initiate the manufacturing process. Proofs may be revised and refined at no additional charge until you are pleased with the design and layout.
Set Up Once your written approval is received, we begin the manufacturing process by creating a life-size replica (also called a pattern) of your plaque. This pattern is set in wax by hand with all the components of your plaque (artwork, emblems, letters, etc.). Once the pattern is complete, two quality control persons meticulously compare the pattern to the approved proof to ensure all details have been translated accurately.
Mold Fabrication Next, the pattern is encased in a special form of slightly moist silica sand (made of 3-part phelonic resin) in a molding box. The sand is then compacted by a process called ramming, which rapidly vibrates the molding box. Once adequately compacted and dried, the pattern is removed, leaving a mold that resembles your plaque in reverse.
Casting Casting begins by melting the bronze into a molten form. Inside a furnace that can reach temperatures above 2,000 degrees Fahrenheit, bronze is melted in a crucible, a container resembling a pot or bucket. When the temperature reaches a level ideal for casting, the crucible is removed from the furnace with a chain hoist. The chain hoist is then used to position the crucible so that the molten bronze can be carefully poured into the mold. Once the mold is filled with molten bronze, it is allowed to cool.
Tooling After the bronze has cooled, the plaque is removed from the molding box. The plaque is then shot blasted and sanded to remove any excess bronze and smooth out the surface where needed. Next, we use several different rotary sanding and grinding detail tools to create the best surface possible without disturbing any of the necessary components (inscription, emblems, etc.).
Finishing After your plague leaves tooling, our artisans apply a color finish by hand to your plaque. American Bronze Craft offers two different finish colors: light brown and dark brown. Using touch-screen infrared paint drying ovens, the paint is quickly dried and cured to ensure a smooth and even finish. Once the paint is dry, your plaque is buffed to remove paint from the raised portions, such as the lettering, to reveal the bronze’s golden color. This step creates a striking contrast to the background finish color and reveals all of the elements of your memorial plaque (inscriptions, emblems and design elements). Before your plaque is complete, we apply a Valve spar clear protective coating to preserve the metal. This coating ensures that your plaque will weather the elements and retain its original beauty and luster for years to come.

Once your plaque is complete, our meticulous quality control personnel carefully examine every aspect to ensure the plaque is free from defects and irregularities before it is shipped for your purposes.

For information on our product guarantees, please download a copy of our terms, conditions and warranty (PDF).

Want to learn more about our production process? Get the inside details with a factory tour. We welcome visitors. Contact us for more details or to find out how to set up a group tour.