Optimization of monumental sculptural processes through 3D modeling, CNC milling, and ceramic shell casting

Abstract This study documents a hybrid workflow for producing a monumental bronze sculpture that combines digital tools with traditional artistic casting. Instead of the conventional route—armature construction, clay modelling, and sectional mould-making followed by wax reproduction—we propose a CNC-machined expanded polystyrene (EPS) core that is directly coated with technical wax. A hollow wax model suitable for ceramic shell casting is obtained by removing the EPS through a localised, controlled acetone-dissolution procedure, avoiding mechanical stress on the wax layers. Execution time, workload, material use, technical feasibility, and formal fidelity were assessed under real workshop conditions. The case study shows a reduction of approximately 55–60% in the time required to produce the wax model, alongside improvements in handling, workshop logistics, and continuity across assembled sections. The protocol is transferable to other large-format works, subject to access to digital modelling/CAM resources, CNC capacity, and appropriate safety measures for solvent use and waste management.