The original relief sculpture has fine detail and some undercuts.
Choosing the right materials: Mold Max® Stroke® is a brushable tin-catalyzed silicone perfect for applying to vertical or even inverted surfaces.
Safety First!: Wear eye protection when working with mold making materials.
Safety First!: Wear gloves when working with mold making materials.
Begin by spraying a thorough coat of Ease Release® 200 release agent over the original model.
Mold Max® Stroke® is measure 100 Parts A to 10 Parts B by weight. Begin by measuring out the A component.
Mold Max® Stroke® is measured 100 Parts A to 10 Parts B by weight. Add an appropriate amount of the B component.
Thoroughly mix Parts A and B together. Be sure to scrape the sides and bottom of the container several times.
Mold Max® Stroke® is white in color. The original model is also white. Adding some Silc-Pig® Red silicone pigment to the Stroke® will ensure thorough coverage when the rubber is applied.
Thoroughly mix Silc-Pig® Red into the silicone.
Continue mixing in pigment until no color striations are present. The silicone is now solid pink in color.
Begin applying Mold Max® Stroke® to the original.
It is important that the first layer of a brush-on mold be applied in a thin coat. This helps eliminate the possibility of entrapping air bubbles.
Be sure to look at the model from all angles. This will ensure thorough coverage. Brush silicone around the outside of the piece to create a flange.
After the first layer has partially cured (approximately 45 minutes), mix and apply a second layer of Mold Max® Stroke®. No pigment is added as the white rubber contrasts well with the first layer.
Cover the entire model and continue building the flange.
This layer can be applied slightly thicker than the first. There will be a total of four layers.
Mold Max® silicone rubber keys are cast into plastic ice cube trays. Mold Maker's Tip: Mold keys are used to help align a rubber mold into a rigid support shell.
Sil-Poxy® silicone adhesive can be used to adhere the keys to Mold Max® Stroke®.
Once the second layer has partially cured (approximately 45 minutes), adhere keys to the outer edges of the mold.
Allow Sil-Poxy® to fully cure (12 minutes) before applying the next layer of Mold Max® Stroke®.
Mix a batch of Mold Max® Stroke® with Silc-Pig® pigment added. Add Thi-Vex® silicone thickener to thicken the batch.
Thickened rubber can be used to quickly fill in undercuts and smooth sharp edges.
Fill in undercuts and smooth sharp edges of the original.
Allow thickened layer to partially cure for 45 minutes before applying the next layer.
Mix and apply another layer with pigment added. Do not added thickener.
Completely cover model and build flange. Allow layer to partially cure for 45 minutes.
Mix and apply a fourth layer of Mold Max® Stroke® with no pigment added.
Cover entire model and flange to complete the fourth layer. The rubber mold should be approximately 3/8'' (1 cm) thick. Allow entire Mold Max® Stroke® mold to fully cure (16 hours).
Using a sharp razor knife, cut excess silicone from the outer edge of the mold. Create straight edges and square off all corners.
Spray the rubber mold and surrounding surface with Ease Release® 200 to separate the support shell from the mold. In some cases, Smooth-On's Sonite® Wax may be necessary to release surrounding surfaces from the support shell.
Creating the rigid support shell: Smooth-On's Plasti-Paste® is a trowelable urethane resin designed to be used for support shells. It is mixed 1 Part A (liquid) to 2 Parts B (paste).
Combine 1A:2B and mix thoroughly.
Mix Plasti-Paste® thoroughly. Be sure to scrape the sides and bottom of mixing container. Mix until there are no color striations.
Apply Plasti-Paste® over cured Mold Max® Stroke®.
Cover the entire mold with Plasti-Paste®. Important: Plasti-Paste® has a working time of 8-10 minutes. Do not mix more material than can be applied in this amount of time.
Mix and apply more Plasti-Paste® as needed. Be sure to apply material beyond the edge of the silicone mold.
Apply at least 3/8'' (1 cm) thickness, making sure rubber mold is thoroughly covered. Large molds may require added thickness for support shell stability.
Wooden blocks are attached to the support shell with additional Plasti-Paste®. These blocks will help level the mold during casting and allow for easier handling.
Once all Plasti-Paste® has fully cured (approximately 90 minutes), carefully remove the support shell from wall.
Plasti-Paste® is strong, durable and lightweight.
Edges of the support shell can be sharp. Sand Plasti-Paste® to make handling safer and easier.
Peel Mold Max® Stroke® mold away from the original piece.
Seat the rubber mold into the support shell. The mold keys added in the previous step will make aligning the mold with the shell very easy.
Once seated, check the level across different axes.
Casting a lightweight reproduction: duoMatrix® NEO is a polymer modified gypsum system that is perfect for casting strong yet lightweight architectural elements. It is mixed 100 Parts A (powder) to 50 Parts B (liquid).
Using a drill mixer, combine powder with liquid.
Mix thoroughly, pausing occasionally to scrape the sides and bottom of container.
Pour mixture into the mold. This first batch will be used to make a ''gel coat'' on the surface of the mold.
Brush the gel coat over the surface of the mold to create a thin layer of duoMatrix® NEO.
Smooth-On's Matrix® Chopped Glass is the perfect chopped fiberglass for layup applications using Matrix products. It adds great strength and durability to a NEO casting.
Matrix® Chopped Glass is added as a percentage to the system. For best results, 6% chopped fiber by weight should be added to the mix.
Soaked glass fiber can be laid up by hand behind the first coat of NEO.
Push chopped glass mixture into deep areas of mold.
Thorough coverage will give the piece the greatest strength and durability.
Mix and apply a second batch of duoMatrix® NEO with no fiber added.
Brush Matrix® over the back of the entire casting.
Once the casting has fully cured (about 1 hour) carefully turn the mold upside down and remove the support shell.
Peel back the Mold Max® Stroke® silicone rubber mold from the Matrix casting..
Mold Max® Stroke® reflects perfect detail captured from the original model. duoMatrix® NEO makes for a perfect casting.
NEO casting is thin, strong and lightweight.
The perfect reproduction: A Mold Max® Stroke® mold can be used many times to reproduce exact replicas of just about any original model.