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
Tim Maslyn helps cut the clay model into sections
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
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
Brush-On® 40 rubber is applied to the piece in four separate layers
Alternate layers of rubber are tinted to assure thorough coverage
Plasti-Paste® is applied to form a strong, light support shell
Mold is removed from clay and has captured perfect detail
Smooth-Cast® 320 liquid plastic is painted onto the surface of the mold
Mold halves are strapped together for rotational casting of plastic
More resin is poured into the mold to strengthen the seam
Rubber mold has recreated every detail of the original
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
Plastic castings are assembled to create a perfect reproduction
The finished casting reflects perfect proportion and detail