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Using EZ-Spray® 45 Urethane to Make a Mold of a Large Fountain

Hyde Park Mouldings was commissioned to create several large concrete fountains to be installed in a newly renovated public garden in New York City. Eli Nassim, a Hyde Park artisan, sculpted the original form out of water-based clay. The final sculpt was over 7 ft. tall (2.1 m.) and incorporated highly detailed ornamentation.

Hyde Park was under a tight deadline. A dedication ceremony was scheduled at the garden within two weeks. A mold had to be made and several reproductions had to be cast and installed in that time period. Mr. Nassim knew that using a brush-on rubber would simply take too long to have all the pieces finished in time. A long-time Smooth-On user, Mr. Nassim contacted our technical help line hoping he might find a faster solution.

Smooth-On's EZ-Spray® 45 urethane system came to the rescue. EZ-Spray 45 is a sprayable mold rubber capable of covering large original models in a very short amount of time. The cured material is not only flexible, but also very durable – more than capable of reproducing the concrete fountain many times over. The deadline was met with time to spare. EZ-Spray 45 urethane picked up every detail from Mr. Nassim's original sculpt, reproducing it in the concrete castings.

The fountains now stand as a reminder that with the right tools and materials, along with the expertise and experience to back it all up, anything is possible with Smooth-On rubbers.
 At over 7 ft. tall (2.1 m.), making a mold of this fountain is a daunting task. The decision is made to use Smooth-On's EZ-Spray® Urethane rubber.  The model is prepped for the mold making process.  A coat of Super Seal® sealer and Universal® Mold Release is applied.

At over 7 ft. tall (2.1 m.), making a mold of this fountain is a daunting task. The decision is made to use Smooth-On's EZ-Spray® Urethane rubber. The model is prepped for the mold making process. A coat of Super Seal® sealer and Universal® Mold Release is applied.
 The EZ-Spray® gun is assembled and connected to an air supply.

The EZ-Spray® gun is assembled and connected to an air supply.
 The EZ-Spray® machine is filled with EZ-Spray® 45 rubber.  The machine is then prepped for spraying.

The EZ-Spray® machine is filled with EZ-Spray® 45 rubber. The machine is then prepped for spraying.
 To test air pressure and ensure proper system flow, some EZ-Spray® 45 is metered into a pail.

To test air pressure and ensure proper system flow, some EZ-Spray® 45 is metered into a pail.
 With the spray nozzle attached, EZ-Spray® 45 is mixed and atomized as it leaves the gun.  A clean, even spray can now be applied to the fountain.  EZ-Spray® 45 can be sprayed into deep undercuts allowing for reproduction of complex originals.

With the spray nozzle attached, EZ-Spray® 45 is mixed and atomized as it leaves the gun. A clean, even spray can now be applied to the fountain. EZ-Spray® 45 can be sprayed into deep undercuts allowing for reproduction of complex originals.
 An assistant brushes EZ-Spray® 45 that has been sprayed onto the fountain, ensuring a thorough, even coat.  Material will remain workable for approximately 10 minutes.

An assistant brushes EZ-Spray® 45 that has been sprayed onto the fountain, ensuring a thorough, even coat. Material will remain workable for approximately 10 minutes.
 EZ-Spray® 45 is sprayed continually over the entire original model.

EZ-Spray® 45 is sprayed continually over the entire original model.
 EZ-Spray® 45 is sprayed onto areas outside the edge of the original.  This will create the mold's flange.

EZ-Spray® 45 is sprayed onto areas outside the edge of the original. This will create the mold's flange.
 A project that may have taken days using a brush-on rubber can now be accomplished in a matter of hours with the help of EZ-Spray® 45.

A project that may have taken days using a brush-on rubber can now be accomplished in a matter of hours with the help of EZ-Spray® 45.

                   
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