Swamimalai Bronze icons: the metal pride of Tamilnadu

 

Swamimalai, a suburb near Kumbakonam is a home for more than 2000 Sthapathis, sculptors and metal artisans. A journey of rejuvenation of traditional handicrafts and culture set forth by our researchers led us to the GI tagged Swamimalai bronze icons (no: 514). This metal craft is mainly famous for the creation of Hindu temple deity statues called ‘Utsavar silai’. Apart from the temple statues, the sthapathis create intricate icons ranging from 6 inches to 12 feet in height. These icons are exported around the world and can be seen at entrance in many star hotels and other affluent areas as a welcome symbol.

Background

The history of bronze icons is traced back to the Chola dynasty. King Raja Raja Cholan summoned many sculptors during the construction of Brihadeshwara temple. These sculptors later settled in Swamimalai region and started to create these superlative bronze beauties. Contrary to the name, these statues are made up of an alloy called Panchloha of five different metals- silver, gold, tin, zinc and copper. The magnificent manual of Shilpa sastra is used as a sculptural grammar, for creating the bronze icons.

Process

Although various other places have tried to make similar bronze statues, Swamimalai bronze icons stand out because of the usage of Vandal mann (alluvial soil) that is available from the banks of river Kaveri. The process starts by making the wax statues, a replica of the icons to be cast. These wax statues are handmade and are repeated every time for each copy. Vandal mann is applied around the wax statue by a process called Karukatuthal, which takes up to 2 days.

Upon baking the above combination, gas is released from one hole and the wax melts via the other hole, creating a hollow clay mould for casting the statue. Simultaneously, the molten alloy is prepared. After burying the clay mould in the earth, the molten metal is poured in and left to cool for two days. Burying underground becomes essential since, the mould should not be disturbed by any movement. Later, the clay mould is hammered and the raw bronze statue is obtained. It is then finished and polished with tamarind extract and soapstone.

Issue Identification

We observed that all these processes were strenuous and tedious. In fact, failure in any one of the stages resulted in repeating the whole process from the beginning. Achieving precision with such techniques was very challenging and also created an unhealthy work environment. The lack of skilled labour resulted in low productivity and no written records were maintained about any of the techniques, tools or processes involved in the making. Above all, most of the bronze icons were sold by weight rather than by piece. “With such low returns, we could not hold back our next generation to stay in this field for livelihood” sadly shared Mr.Venkatesh, a master craftsman.  

Technological interventions

We came up with few interventions that would walk the art form into the modern age, especially by up skilling the artisans with new technologies. Usage of vacuum casting machine that could do the entire process, from casting till finishing in one go within a short span of time were taught to them. The statues were scanned and recreated for wax models using 3D printing technology. Wax gun model, that could easily detail out intricate ornaments was conceptualised. However, we did not want to replace the tradition of making Utsavar icons which involves multiple holy rituals. These traditions are to be valued and not to be meddled with. 

Entering the Entrepreneurial culture

·       Sudharshana Jwala - a casting centre at Swamimalai to make icons with traditional and innovative technologies.

·       Abinaya Traditional Arts and Wax modelling school - by Mr.Saravanan, another master craftsman and a wonderful artist, aims to teach the art of intricate wax modelling.

·       Siva Kuru - by Sathish, who teaches softwares like Rhino, Z Brush, Artcam and Matrix Gold to create e-catalogue for the designs and to create source files for the icons thus making it available to everyone for further reference and casting.

·       Z 3d prints - by researcher Aravind, to create digital fabrication and to make customised 3D prints for the traditional and contemporary designs based on Shilpa Shastra. 

Tool documentation and Digital Assistance

The different types of hand tools used for the various stages were documented, engineering drawings were created and made as an e-catalogue and book in the name of ‘Traditional Metal Crafts tool Book’ for future reference. VR museum was developed that enabled the sthapathis to provide interactive and vibrant interface for customers. AR enabled catalogues were designed, that allowed customers to customize the size, material and weight of the statue according to their desire.

Ergonomic Analysis

The wax model makers had to lean to pick the tools every time while fashioning the wax models. Also they sat on a manapalagai (low height floor sitting chair- without back rest) for long hours which caused multiple strains. After studying the work postures and processes, we designed a wax modelling table with manual blower compartments and a chair tailor made to alleviate the body stance.

Beneficiaries

I am proud to share that this expedition by our team, has helped out 15 artisans and has been a wonderful rendezvous of technology and tradition.

 

Giving a voice to the unvoiced

Swastha Ilangovan

Team Kural