Design & Scale Studies — Sketches, CAD roughs, and physical maquettes determine stance and proportion.  

Material Prep — Plate and bar stock selection; cutting, forming, and fixture setup.  Assembly — Weld sequences designed to control heat distortion; fixturing ensures geometric accuracy.

Refinement— Grinding, edge-shaping, and surface correction to accentuate light planes.  

Finish— Patinas, high-gloss coatings, or color systems for contrast and durability.  

Pattern Making — Wax, 3D-printed resin, or foam masters used for complex shapes.  

Gating / Spruing — Flow-balanced design to minimize turbulence and defects.  

Shell Building — Alternating slurry and stucco layers; dry between coats until proper shell thickness.  

Burnout & Pour — Dewax, shell preheat, and controlled metal pour (bronze, iron, or aluminum).  

Breakout & Chase — Shell removal, gate cutting, surface chasing, and weld integration.  

Patina & Seal — Chemical patinas or heat-based coloration; sealed for longevity. 

CAD Modeling — Parametric form exploration for proportion and dynamic balance.  

Rapid Maquettes — PLA or resin prints test scale, stance, and shadow geometry.  

Joinery Planning — Hidden alignment pins and sectioning for large-scale fabrication.  

Scale-Up — Templates and jigs ensure accuracy when transferring from model to full-size steel.