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I am making a brush on rubber mold and want to know how many square feet (meters) a unit of mold rubber will cover.

For a quick chart of commonly requested coverage rates - CLICK HERE

The approximate coverage area depends on how much material is contained in a unit (A+B by weight) and what the material yields on a cubic inches/lb. or cubic centimeters per kg. basis. Since each brushable mold rubber has a different yield as measured by cubic inches/lb. or cubic centimeters per kg., coverage rates will vary.

Example - Doing The Math

Calculating the coverage of a 1 gallon unit of Mold Max® Stroke;

• A 1 gallon kit of Mold Max Stroke (A+B) contains 11 lbs.
• The cubic inch/lb. yield of Mold Max Stroke is 23.5 inches.

1. 11 lbs. x 23.5 cubic inches per pound = 259 cubic inches
2. Divide 259 cu. in. by .375 (3/8") = 691 square inches
3. Divide 691 by 144 (no. of square inches in a square foot) = 4.8 square feet
4. 4.8 square feet (0.45 m2) is coverage of a gallon unit of Mold Max applied 3/8" thick.

Calculating the coverage of a 5gallon unit of Mold Max® Stroke;

• A 5 gallon kit of Mold Max Stroke (A+B) contains 55 lbs.
• The cubic inch/lb. yield of Mold Max Stroke is 23.5 inches.

1. 55 lbs. x 23.5 cubic inches per pound = 1,293 cubic inches
2. Divide 1,293 cu. inches by .375 (3/8") = 3,448 square inches
3. Divide 3,448 by144 (no. of square inches in a square foot) = 24 square feet
4. 24 square feet (2.23 m2) is coverage of 5-gallon unit of Mold Max applied 3/8" thick.

The following offers flat-area coverage rates for some of Smooth-On's brushable mold making rubbers. The below values assume a final rubber thickness of 3/8" / 0.95 cm,
4 layers of rubber applied as directed.

Rubber Product Coverage

Mold Max® Stroke - 1 Gallon Kit (11 lbs. / 4.99 kgs.) 4.8 ft.² / 0.45 m²
Mold Max® Stroke - 5 Gallon Kit (55 lbs. / 24.95 kgs.) 24 ft.² / 2.23 m²

Rebound® 25 - 1 Gallon Kit (16 lbs. / 7.26 kgs.) 7 ft.² / 0.65 m²
Rebound® 25 - 5 gallon Kit (80 lbs. / 32.29 kgs.) 35 ft.² / 3.25 m²

Brush-On™ 35 - 1 Gallon Kit (13.4 lbs. / 6.08 kgs,) 5.34 ft.² / 0.50 m²
Brush-On™ 35 - 5 Gallon Kit (75 lbs. / 34.02 kgs.) 29.86 ft.² / 2.77 m²

Brush-On™ 40 - 1 Gallon Kit (18 lbs. / 8.16 kgs.) 7.87 ft.² / 0.73 m²
Brush-On™ 40 - 5 Gallon Kit (90 lbs. / 40.82 kgs.) 39.33 ft.² / 3.65 m²

Brush-On™ 50 - 1 Gallon Kit (18 lbs. / 8.16 kgs.) 6.33 ft.² / 0.59 m²
Brush-On™ 50 - 5 Gallon Kit (90 lbs. / 40.82 kgs.) 32 ft.² / 2.97 m²

Brush-On™ 60 - 1 Gallon Kit (18 lbs. / 8.16 kgs.) 6.33 ft.² / 0.59 m²
Brush-On™ 60 - 5 Gallon Kit (90 lbs. / 40.82 kgs.) 32 ft.² / 2.97 m²



The FAQ list is offered as a guideline and offers possible solutions to problems encountered during mold making and casting. No warranty is implied and it is up to the end user to determine suitability for any specific application. Always refer to the provided Technical Bulletins (TB) & Material Safety Data Sheets (MSDS) before using any material. A small scale test is suggested to determine suitability of any recommendation before trying on a larger scale for any application.



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