The Making of a Mondo

1st: After the customer has given me their wrist measurements, and we agree on the size they need, a model is made (if I have not had to make one in that size before). Models may be made through several processes. The process I use depends on the complexity of the model needed, the detail needed, and my available time. Processes commonly used are:

1. Hand Carving in Wax or some other carvable material: This is a very time consuming and tedious task, at times taking several hours to get the model the way I like it. However it is unavoidable in some cases.
2. Computer Controlled Carving from a 3D computer generated file: Here, I would make the 3D file and then send it out for fabrication. A component made this way can run anywhere from about $50 up to several hundred. The models are very good, but the surface finish is lacking, so there is a bit of "clean-up" work associated with the model.
3. SLA Part Generation from a 3D Model: In the SLA process a special machine takes a computer file and lays down layers of wax or plastic and eventually "builds" the model from the ground up. SLA costs start around $100 and can go up to around $300 depending on the design and the detail needed. The finish is generally better than the last process, but there is still a bit of "clean-up" work.
4. ZCORP Part Generation from a 3D Model: The ZCORP process is essentially the same as the SLA process, but much rougher. ZCORP costs start around $30 and can go up to around $150 depending on the design. The finish sucks but it is less time consuming to "clean-up" the piece than to carve it from scratch. *The First two pictures to the left are ZCORP models after being cleaned up.

2nd: After "clean-up", the model is sent to a metal caster, where rubber molds are made from the original model for a cost of about $75 (Pics 3&4).

3rd: The caster then uses the molds to reproduce the design in precious metals through a long and drawn out process called "lost wax" casting. I am charged a labor fee for each rough metal casting in addition to the cost of the raw metal. Pics 5&6 show what the raw casting looks like right out of the box from my caster in Sterling. Pics 7&8 show what they look like in 10k gold. (Not too pretty eh?)

4th: The raw casting is hand processed by myself as follows:

1. The Sprue (that knobby thing you see sticking out the side of the castings above) is ground off with hand tools.
2. The piece is roughed over with a series of files.
3. The alignment and fitment of the piece is checked and adjusted till it works.
4. The piece is sanded with multiple grades of sandpaper; starting with very rough, and working down to a very fine paper.
5. The piece is buffed to an almost mirror finish.
6. Any attachments or Fixes are Welded to the piece at this point; which ruins the surface finish.
7. Another round of sanding takes place.
8. The piece is buffed to an almost mirror finish.
9. A final check of the piece is made.
10. A final buff is done.
11. The piece is washed to remove any buffing residue. (I don't always get it all)
12. A hand buffing is done.
13. The product is packed and shipped.

Now, to give you some idea of the time this 4th stage takes; the finished bracelet to the left took about 4 hours of work after getting it back from my caster.

Figuring all that time and expense into the final product, do you still think I am charging too much for my designs?

This is a typical process that a cast piece goes through. However, If it is a hand-fabricated piece, like my collars, the labor can be even more intensive while I attempt to manipulate the metal to your needs.

You will be getting a quality product when you order from me. I guarantee it!