The pewter-like alloy is poured slowly into a mold and cools quickly. But it takes 40 hours of precise and delicate work before Oscar is ready for the bright lights of Hollywood.
The heart of the trophy - with its iconic square jaw, broad chest and sword - is swiftly hammered out in preparation for careful polishing.
Once every blemish is erased and Oscar shines like a mirror, the statue is hand-dipped in electrically-charged tubs of molten copper, nickel, silver and 24-carat gold.
Then it's on to more polishing and a blinding lacquer before Oscar is finally screwed into his heavy base and carefully boxed using white gloves.
Hand-casting is a dying art, but one the Academy is willing to pay dearly for as it jealously guards the reputation of one of the most sought-after and recognized trophies in the world.
The perils of seeking cheaper alternatives were on display at the Golden Globes last year when Robert De Niro showed up empty-handed in the press room after receiving a lifetime achievement award. (AFP)
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