Lost-Wax Microfusion in Brass & Bronze
Microfusion (lost-wax casting) is a high-precision process used to produce premium metal components in brass or bronze with complex shapes, fine details, and organic forms that cannot be achieved through standard die casting.
This process is ideal for jewellery-quality hardware, luxury accessories, and distinctive designs where surface quality and detail are essential. Microfusion is commonly used for small to medium production runs and allows greater design freedom compared to zamak pressurised die casting.
This FAQ section explains how microfusion works, what is required to start, achievable tolerances, finishing steps, and how to optimise costs while maintaining quality.
Microfusion is often chosen when design complexity, detail, and material value are more important than high-volume production speed.
MICROFUSION BRASS OR BRONZE FAQs
What’s the difference between brass and bronze for accessories?
Both are premium copper alloys, and both work very well for microfusion. The best choice depends on the look, finishing, and the “feel” you want.
- Brass (Copper + Zinc)
Colour/feel: typically more yellow-gold and “bright” in tone.
Finishing: generally easier to polish to a high shine and gives an excellent base for galvanic plating (gold, nickel, light antique effects, etc.).
Use cases: fashion hardware where you want a clean, bright, luxury look and consistent plating results. - Bronze (Copper + Tin, sometimes other elements)
Colour/feel: usually warmer / more reddish-brown than brass, often perceived as more “classic” or “heritage.”
Finishing: also polishes well, but it’s especially appreciated for antique, vintage, and brushed finishes because the base tone supports those looks naturally.
Use cases: premium accessories where you want a warmer tone or a more “traditional” character under antique or brushed galvanic. - Strength & durability (practical view)
Both are strong and suitable for premium accessories. Depending on the exact alloy, bronze can feel slightly “tougher” in wear, but for most accessories, the decision is mainly aesthetic + finishing + cost.
If the client has a target look (bright gold / light antique/deep antique / brushed), we can recommend the best option and, if needed, provide a sample to validate colour and finishing.
What do you need from me to start (master / file / sample)?
We can work from a 3D file (STEP preferred) or from a physical master sample. For microfusion, the master is typically made in brass or resin, and then we create a silicone mold for wax injection.
Why do we need a silicone mold first?
Because microfusion is a repeatable process only be done when we can inject wax copies. The silicone mold lets us create identical wax parts, assemble them on a tree, then cast multiple pieces in one cycle.
Does microfusion leave a parting line like die-casting?
Normally no visible die-casting parting line. You may still have sprue marks (feeding points) that are removed and finished during post-processing.
Frequently asked question
Use this text to answer questions in as much detail as possible for your customers.
What shapes are best for microfusion?
Microfusion is ideal for: organic curves, deep relief, engraved logos, textures, and 3D forms that would be difficult or expensive in die-casting.
Can you cast undercuts and deep details?
Yes — microfusion handles undercuts and deep relief much better than die-casting. Just remember: the more complex the geometry, the more important the wax release and the more careful the finishing.
Can I add text, logos, or engraving?
Yes. Microfusion is excellent for logos, serial marks, and engraving, especially for premium accessories.
What tolerances should I expect?
Microfusion is very precise for casting, but it’s still a casting process. If you need tight fits (pins, slots, screw holes), we recommend post-machining/drilling after casting.
Can holes be cast directly (for rivets/screws)?
Small holes can be cast, but for reliable assembly, we usually cast a pilot shape and then drill/finish tothe final size.
Can parts be CNC-finished after microfusion?
Yes — we can drill, face, refine edges, or add functional details after casting (useful for buckles, hinges, precision fits).
What finishing steps are included before galvanic?
Microfusion requires more manual work: sprue removal → assembly (if needed) → polishing → preparation for galvanic.
Is there a MOQ for microfusion?
No fixed MOQ — microfusion can be made in very small batches. Cost per piece decreases when we can fill trees efficiently, so higher volume = lower unit cost.
How fast is production?
Typical production time is 10–15 working days (depending on quantity, finishing level, and galvanic scheduling).
How do I reduce cost without changing the design too much?
Best levers:
- Increase the quantity to fill trees efficiently
- Reduce extreme thin sections and sharp corners (less scrap + less polishing)
- Avoid unnecessary deep cavities that trap wax or require heavy finishing
- Standardise sizes where possible (same mold family)
Can you match a “jewellery-grade” surface?
Yes, microfusion is chosen specifically when you need high surface quality—but the final result depends on the requested polish level and the geometry (deep textures vs mirror polish).
What are the typical product types you recommend microfusion for?
Premium: jewellery components, high-quality bag hardware, shoe ornaments, pet accessories, belt accessories, decorative buckles, logo plates, and sculpted shapes.