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The limits of precision casting were explored experimentally at the Bronze Casting Workshop at Wilhelminaoord, the Netherlands, by making wax models, moulds and lost wax castings using essentially early metalworking conditions. Geometrically patterned models of Dark Age type dies were used to make wax patterns to simulate one of the finest detailed objects to come from excavation, the Tjitsma die. Examination of mould surfaces and castings by scanning electron microscopy showed that the limiting surface resolution of lost wax casting in bronze was the finely textured dendritic cast surface. The mould surfaces had taken the geometric pattern of the original wax models very well, although there is a fine particulate texture to the mould surface, but this is far finer than the limiting dendritic surfaces of the cast bronze.

This article examines the challenges and limitations of precision casting through experimental bronze casting using early metalworking techniques. The study focuses on creating detailed wax models and molds to replicate the Tjitsma die, an archaeological object. The research reveals that the surface resolution in lost wax casting is limited by the textured dendritic cast surface. The article discusses the factors that affect the reproduction of fine details in cast metal, such as surface tension and shrinkage. The study conducted a series of experiments in Sweden to achieve highly detailed castings using early medieval techniques. The results showed that while the castings displayed good detail, there were some casting faults. The article concludes that the dendritic surface texture is the main limiting factor in achieving high-resolution surface detail. The text also explores the process of precision lost wax casting and its application in reproducing intricate patterns on bronze objects. The experiments involved creating wax models, making clay molds, and casting bronze using different techniques and materials. The results varied in terms of successfully reproducing the desired patterns, with some castings showing good detail and others having defects or bubbles. The study also compared the patterns on the castings with those found on gold foils from the Sutton Hoo archaeological site, noting similarities in the "boxed" patterns. [Extracted from the article]