I first became interested in lost-wax casting and jewelry design when I was around eleven years old. At the time, I learned how to make moulds and wax models. Decades later, that interest returned after I came across a Lord of the Rings band and decided to explore how such a piece could be reproduced with genuine precision.
The first step was to find a reference that was as accurate as possible so that I could establish the correct dimensions, curvature, and proportions. That proved more difficult than expected. Even Weta appeared to have used two slightly different shapes for what was presented as the same band.
Before settling on Weta’s version as the most reliable reference, I examined several other replicas. All of them were inaccurate in one way or another, and some were unsuitable as a serious basis for modelling.
At the same time, 3D design itself was entirely new to me. That alone would have been enough of a challenge, but the production process introduced a second layer of complexity. Lost-wax casting may be straightforward in principle, yet the practical outcome depends heavily on the exact process, tooling, and materials used.
Would the metal be melted with an induction-based machine and protected with argon gas to achieve a cleaner cast? Would vacuum, pressure, and vibration be combined to improve density and reduce defects? Which printer and which wax or castable resin would produce the best model? Which investment material would offer the best balance between dimensional stability, surface quality, and predictable shrinkage? And would the investment itself be mixed and poured under vacuum and vibration to minimise imperfections?
It was a long and exacting process. After many attempts, and without compromising on the production method, I was eventually able to achieve the result shown below.
The next step is to develop a deeper working knowledge of Rhinoceros. I chose to invest time in it because the integration of Grasshopper makes parametric modelling far more accessible, especially when combined with Python scripting. This page shows the final results of that process.
LOTR replica placed on top of Weta’s box.
LOTR replica with original chain.
Elvish Love band in 18ct pink gold. The male band weighs 15.858 grams.
The Elvish love poem is laser-engraved around the outside of the band. On the inside, the text Grow Old With Me is engraved in the typeface used in the movies.