This may not solve your problem in that it takes a new learning
cycle. I just thought it might be interesting to describe the use of
thin copper molds to create wax items.
I originally made large copper western pictures by working the
design into a thin sheet of copper. The design is raised by worked
on both sides of the copper with wooden tools. When the design is
done you have a raised embossed copper picture.
The back of the raised embossed design is filled with plaster then
the whole thing is contact cemented to a piece of masonite.
Every now and then the plaster would fall out of the back of the
copper picture. The plaster was an exact copy of the original
I developed a way to make the plaster look like copper which allowed
me to reproduce the pictures. The last one I created was a buffalo
hunt scene which was 15 by 26 inches. The only problem was that the
plaster, which was about one half inch thick, would crack easily.
Looking for a way to make the casting more durable lead me to lost
wax casting which lead to lost wax jewelry making.
The first jewelry items I created were buckles with various western
portraits on them. Just pour molten wax into the raised embossed
copper mold that was sprayed with a mold release. When the wax
hardened it was into the freezer then out to cool to room temp. The
wax with a raise portrait would pop out of the copper mold.
I eventually made RTV molds of the buckles which made it easier to
The material and instruction manuals were obtained at a local Tandy
store which is no longer in business. There is a tandy company that
still supplies miscellaneous crafts item. They might be found on the
I can send photos to anyone interested.