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

Hyde Park Mouldings (www.hyde-park.com) 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. 


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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.
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The EZ-Spray® gun is assembled and connected to an air supply.
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The EZ-Spray® machine is filled with EZ-Spray® 45 rubber. The machine is then prepped for spraying.
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To test air pressure and ensure proper system flow, some EZ-Spray® 45 is metered into a pail.
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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.
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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.
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EZ-Spray® 45 is sprayed continually over the entire original model.
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EZ-Spray® 45 is sprayed onto areas outside the edge of the original. This will create the mold's flange.
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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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