1 - Our model is a detailed urn made of concrete.

2 - Urn is measured for dimensions.

3 - Acrylic coated boards are cut to size.

4 - Mold box walls will follow the contour of the model.

5 - Construct mold box and secure with drywall screws.

6 - Two handles are attached to mold box to make handling easier.

7 - Use a black marker to mark inside edge of mold box to define clay bed perimeter.

8 - Remove mold box to expose perimeter line.

9 - Form a 3/4'' (2 cm) thick clay bed inside marked area.

10 - Place mold box over clay bed.

11 - Fill any voids with additional clay.

12 - Use a rolling pin to smooth out clay bed.

13 - Smooth beveled edge around perimeter.

14 - Drill vent hole: Allows air to escape during mold making process.

15 - Make a clay gasket around perimeter.

16 - Center urn on clay bed.

17 - Firmly push urn into clay bed.

18 - Registration key is cut into clay bed with large paper clip.

19 - Overhead view showing registration key in clay bed.

20 - Apply Superseal® sealing agent to urn surface.

21 - Apply Universal® Mold Release to mold box and urn.

22 - Place mold box over urn.

23 - Seal seams with hot melt glue.

24 - Dispense ReoFlex® 40 mold rubber 1A to 1 B by volume.

25 - Mix thoroughly for three minutes, scraping bottom and sides of container.

26 - Pour rubber into cavity and let mold rubber cure for 16 hours at room temperature (72F / 23C).

27 - DO NOT COVER BOTTOM OF ORIGINAL MODEL. Exposed area will represent pour spout.

28 - Next day, flip over mold box.

29 - Slowly remove baseboard.

30 - Remove rubber flashing.

31 - Carve notch into rubber with a knife for registration.

32 - Inside the mold box is marked to identify registration point.

33 - Apply Superseal® sealing agent to the inside of the urn.

34 - Apply Universal® Mold Release to mold box and urn.

35 - Clean modeling clay off baseboard. Once cleaned this will be used for the core section base.

36 - MAKING THE CORE SECTION. Place a plastic container on the center of baseboard and mark outline.

37 - Drill four 1'' (2.5 cm) holes. This is where the mold rubber will be poured to make the second half.

38 - 1/4'' (6mm) vent holes will be drilled in highlighted areas.

39 - Vent holes will minimize air bubbles in cured rubber.

40 - Hot melt glue is used to adhere plastic container to center of board.

41 - Hold in place for ten seconds.

42 - Place core section into mold caviity. Alignment point is marked on the outside of base and mold box.

43 - Adhere core section with drywall screws.

44 - Use modeling clay to seal seams.

45 - Dispense ReoFlex® 40 mold rubber 1A to 1 B by volume.

46 - Mix thoroughly for three minutes, scraping bottom and sides of container.

47 - Pour rubber into cavity.

48 - Let mold rubber cure for 16 hours at room temperature (72F / 23C).

49 - Remove drywall screws and slowly lift-up core section.

50 - Remove mold box.

51 - A sharp knife is used to extract the original model.

52 - Mold reflects perfect detail captured from the original model.

53 - Apply Ease Release 2831 to all rubber surfaces.

54 - Use alignment point to help assemble mold for casting.

55 - Reproduction will be made with duoMatrix® NEO (Polymer Modifed Gypsum). Mix ratio 2 Parts A to 1 Part B by volume.

56 - One part play sand will be added for addional texture.

57 - Mix all components thoroughly for three minutes, scraping bottom and sides of container.

58 - Add So-Strong® Brown pigment to mix for color.

59 - Pour Matrix NEO slowly into cavity.

60 - After Matrix® NEO cures for 90 minutes remove mold box.

61 - Demold casting from the rubber mold.

62 - Perfectly detailed reproduction of the original model.

63 - Add color to the casting with brown wood stain.

64 - Wipe-off any extra stain with soft towel.

65 - Rubber mold is ready for production casting.

66 - Different finishes can be achieved by varying color, tints and stain.