You just have to be able to think upside down and backwards, which sounds complicated but it’s really not. Most of what we do in the mold and casting department involves creating a brand new “part” out of a combination of chemical reactions, artistic technique and mechanical technologies.
First we create a mold out of a variety of materials…plaster, urethane, fiberglass, epoxy or silicone just to name a few. Then we choose a suitable casting material by asking a series of important questions. Will the part be clear or tinted? Does it need to be hard enough to sand or soft enough to flex? Will it allow for proper adhesion for the paint finish?
Once those questions have been answered, we ask some more.
Will the mold be used to hand laminate the part or will it receive a spray-coating or injection? Can the part be roto-cast? Which variation of pressure, vacuum, motion or temperature will be used in the casting process? And how many times can the mold be used before it begins to fail?
At this point, the challenge becomes one of consistency. Acceptable parts need to be uniform and free of flaws and air bubbles. Even though every drop of material that goes into a mold is measured to the gram and temperatures carefully monitored, parts have way of coming out differently. Constant vigilance and concentration are required by our team to ensure that each piece comes out as well as we can make it. In the mold and casting department, we care a great deal about making a good impression.
You see what we did there? Impression? Mold and casting.