Smooth-On Mold Making and Casting Materials
Home Technical Info How To Frequently Asked Questions Media Gallery News Find a Distributor Mold Makers Directory
McAfee SECURE sites help keep you safe from identity theft, credit card fraud, spyware, spam, viruses and online scams
About Us Seminars Tech Support Contact My Account Buy Now Smooth-On Home enews
Material Calculator
and Unit Convertor
Custom Formulating
Newsletter Signup

Get Smooth-On's Greatest Catalog Ever! Click Here
Molding A Complex Original Model

Ever wonder how to make a mold of a complex original? Sculptor Bill Kilpatrick’s exquisite creation entitled "Celebration" posed just such a molding challenge. Sculpted from Chavant® modeling clay, the piece had delicate detail, complex angles and severe undercuts that would test even the most experienced mold maker. Tim Maslyn, of Tim Maslyn Studios, had a simple answer: "break it down and make multiple molds and castings."

The goal was to reproduce the detail of the piece exactly. Mr. Kilpatrick need multiple castings for upcoming exhibitions, and the finished castings had to be inexpensive and lightweight. Conventional molding and casting methods did not lend themselves to this application.

Each porcelain-like reproduction made was identical to the original clay sculpture. An assembled finished casting weighs less than 40 lbs. and can easily be carried by one person. The original weighed over 300 lbs.
 Bill Kirkpatrick touches up his original clay sculpture

1 - Bill Kirkpatrick touches up his original clay sculpture
 Tim Maslyn helps cut the clay model into sections

2 - Tim Maslyn helps cut the clay model into sections
 Maslyn clays up the female model for molding

3 - Maslyn clays up the female model for molding
 The clay shim provides a flange to support the first half of the mold until rubber and support shell are cured

4 - The clay shim provides a flange to support the first half of the mold until rubber and support shell are cured
 Channels are carved into clay to form a tight fit for rubber mold halves

5 - Channels are carved into clay to form a tight fit for rubber mold halves
 The female portion of the sculpture has been shimmed so two rubber mold halves will fit together

6 - The female portion of the sculpture has been shimmed so two rubber mold halves will fit together
 Brush-On® 40 rubber is applied to the piece in four separate layers

7 - Brush-On® 40 rubber is applied to the piece in four separate layers
 Alternate layers of rubber are tinted to assure thorough coverage

8 - Alternate layers of rubber are tinted to assure thorough coverage
 Plasti-Paste® is applied to form a strong, light support shell

9 - Plasti-Paste® is applied to form a strong, light support shell
 Mold is removed from clay and has captured perfect detail

10 - Mold is removed from clay and has captured perfect detail
 Smooth-Cast® 320 liquid plastic is painted onto the surface of the mold

11 - Smooth-Cast® 320 liquid plastic is painted onto the surface of the mold
 Mold halves are strapped together for rotational casting of plastic

12 - Mold halves are strapped together for rotational casting of plastic
 More resin is poured into the mold to strengthen the seam

13 - More resin is poured into the mold to strengthen the seam
 Rubber mold has recreated every detail of the original

14 - Rubber mold has recreated every detail of the original
 The female model is reproduced as a hollow casting identical to the original.

15 - The female model is reproduced as a hollow casting identical to the original.
 Foam-iT!® 5 is poured into the casting to provide structural strength

16 - Foam-iT!® 5 is poured into the casting to provide structural strength
 Plastic castings are assembled to create a perfect reproduction

17 - Plastic castings are assembled to create a perfect reproduction
 The finished casting reflects perfect proportion and detail

18 - The finished casting reflects perfect proportion and detail

                   
Smooth-On, Inc. Copyright © 2011
2000 Saint John Street, Easton PA 18042 | Order Desk: 800.762.0744 | Fax: 610.252.6200 | Tech Help: 800.381.1733 or 484.546.0466

E-Commerce Solutions