Taking The Mystery Out Of Creating A Concrete Sink Mold

Taking The Mystery Out Of Creating A Concrete Sink Mold

With more and more architectural concrete companies offering various decorative sink lines we present the following “how-to” so you too can make your own. Concrete is an attractive material with a unique quality look and feel. Concrete is a "perfectly imperfect" material, it will vary from piece to piece and that is part of its charm and uniqueness.

The following step-by-step uses Smooth-On's VytaFlex® 40 mold rubber to achieve a perfect mold that can handle multiple castings. Just remember that you can make a mold of just about anything so get creative in designing your new sink basin.

1 - The model: concrete sink basin.	2 - Sink basin is measured for dimensions. Acrylic coated boards are used to construct the mold box walls, spacer board and two baseboards.	3 - Basin is centered on the acrylic coated board.
4 - A pencil outline is drawn around perimeter of basin.	5 - Use a jigsaw to cut out the circular pattern. This will be used as a spacer.	6 - Remove plug.
7 - Place sink on baseboard and place spacer on top.	8 - Mark alignment on baseboard and spacer board.	9 - Use modeling clay (sulfur free) to create gasket around perimeter of basin.
10 - This will prevent rubber from going underneth model.	11 - Placer spacer down over basin.	12 - Use modeling clay to fill in negative space caused by the spacer.
13 - Glue down acron nuts in corners for registration keys.	14 - Place one extra acron to help with alignment.	15 - Assemble mold box with drywall screws.
16 - Seal seams with hot melt glue.	17 - Release all surfaces with Universal Mold Release.	18 - Measure and dispense VytaFlex® 40 mold rubber.
19 - Mix thoroughly for three minutes, scraping bottom and sides of container.	20 - Pour VytaFlex® mold rubber 40 slowly over model. DO NOT COVER BOTTOM OF ORIGINAL MODEL. Exposed area will represent pour spout.	21 - Let VytaFlex® 40 mold rubber cure for 16 hrs. at room temperature (72°F / 23°C).
22 - Use modeling clay to fill in any surface irregularities.	23 - Place reverse baseboard down over cured rubber.	24 - Secure board with drywall screws.
25 - Turn over mold box.	26 - Remove original baseboard to expose model.	27 - Remove spacer board.
28 - Remove clay gasket and wipe surface clean.	29 - Fill any screw holes with modeling clay.	30 - Hot glue exposed seams.
31 - Apply Univeral® Mold Release to all surfaces.	32 - Measure and dispense VytaFlex® 40 mold rubber.	33 - Mix thoroughly for three minutes, scraping bottom and sides of container.
34 - Pour VytaFlex® 40 mold rubber over model and existing rubber to create second half of mold.	35 - Let VytaFlex® 40 mold rubber cure for 16 hrs. at room temperature (72°F / 23°C).	36 - Once cured, remove mold box side walls.
37 - Slowly remove top section of mold.	38 - Remove original sink basin.	39 - A perfect 2-part mold of the original model.
40 - Apply In and Out II® release agent to all surfaces.	41 - Place mold between boards and secure.	42 - Place mold on a vibration table and fill with concrete.
43 - After concrerte cures for 24 hours, demold casting.	44 - A perfect concrete reproduction of the original.	45 - Rubber mold is ready to be cast again.