Arcosanti bell production is the primary economic engine for the experimental town Arcosanti, generating crucial funding to support The Cosanti Foundation and its architectural mission. Conceived by Italian-American architect Paolo Soleri in the mid-20th century, these famous handcrafted wind bells—sold globally under the Cosanti Originals brand—are produced daily by resident artisans using specialized, primitive-yet-innovative earth and silt casting techniques. Production takes place both at Arcosanti in Mayer, Arizona, and its sister site, Cosanti, in Paradise Valley.
Bronze Bell Production (Sand Casting)
The production of the iconic bronze wind bells relies on a highly specialized sand-molding method executed inside the architecturally renowned Foundry Apse.
•Molding: Artisans densely pack sand around aluminum master patterns inside two-piece boxes called snap flasks using a wooden mallet.
•Hand-Carving: Once the mold is separated, artisans carve completely unique geometric or abstract designs directly into the sand cavity upside down and inside out. [1]
•The Pour: Silicon bronze ingots are heated in a furnace to approximately 2,200 to 2,400 degrees Fahrenheit. The molten bronze is manually guided via a crucible and poured directly into the sand molds through a carved tunnel or sprue.
•Finishing: The cast metal solidifies rapidly. Once cooled, the bells are treated with specific chemicals to accelerate a green verdigris patina, or they are hand-burnished for a sleek metallic finish.
•Assembly: Each bell is individually fitted with a custom clapper, a connecting chain, and a distinctive bronze fin (or "kite") designed to capture the desert wind.
Ceramic Bell Production (Silt Casting)
Alongside bronze work, Arcosanti manufactures a highly popular line of textured ceramic wind bells using native Arizona clay.
•Silt-Cast Method: This technique is a miniature reflection of how Arcosanti's massive concrete structures were constructed.
•Crafting: Artisans shape dense mounds of damp silt and earth to serve as the structural mold core.
•Etching: Detailed motifs, southwest impressions, and freeform textures are hand-carved directly into the clay surface before firing.
•Uniqueness: Because the base silt mold breaks away or shifts during production, no two ceramic bells share the exact same shape or design.