Saturday, November 12, 2011

9. MOLD MAKING and CASTING

The MOLD MAKING AND CASTING process is an essential method for creating multiples. This process is also necessary for transforming a model made in a non-permenant material such as oil clay, into a permanent or more desirable material such as polyurethane resin, fiberglass, Aqua-Resin, concrete, Hydrocal plaster, glass, or metal. Alternative media are frequently used as a casting material; this may include silicone rubber, latex, dirt, sawdust, chocolate, soap, candy glass, salt, sugar, etc.

Material Sources:
-The Compleat Sculptor (TCS)
Phone: Outside NY City: 800-9-SCULPT Inside NY City: 212-243-6074
Location: 90 Vandam Street New York NY 10013

-Smooth-On
Phone: (800) 762-0744
Location: 2000 Saint John Street Easton, Pennsylvania 18042

Common Rubber Mold Materials Needed:
-Mold Rubber (Silicone, Polyurethane or Latex) Or use Pottery Plaster for ceramic slip-casting
-Mixing buckets
-Mixing and measuring cups such as disposable drink cups
-Mixing sticks: tongue depressors, firm spatula, paint paddle
-Release spray such as Mann's Ease Release 200, check compatibility with media
-Sealant for porous surfaces Smooth-On Super Seal
-Cardboard or foamcore for mold boxes
-Duct tape
-Hot Glue
-X-acto knife
-Disposable rubber gloves
-Disposable 1" chip brushes
-Plastic Sheeting

Common Mother Mold Materials Needed (as a support for Brush-on Molds Only):
-Plaster (such as Hydrocal, avoid Plaster of Paris)
-Burlap
-Scissors
-Oil and Water based clay for clay walls and keys
-Aluminum Flashing for Shim, soda cans ok
-Vaseline 
-Disposable 1" chip brush (for Vaseline) 
-Alternate Option: Smooth-on brand "Plasti-Paste"

Common Casting Materials Needed: 
-Casting material such as Polyurethane Resin (Smooth-On Smooth Cast 300), Smooth-On Foam it! casting foam, Plaster, Wax, Ceramic Slip, Concrete, Chocolate, Soap, etc
-Mixing buckets
-Mixing and measuring cups such as disposable drink cups
-Mixing sticks: tongue depressors, firm spatula, paint paddle
-Release spray such as Mann's Ease Release 200, check compatibility with media
-Disposable rubber gloves
-Disposable 1" chip brushes
-Plastic Sheeting
-Clean up casting with x-acto kife, small files, and sandpaper. 
-Fill any holes with an epoxy putty such as Magic Sculpt available at the Compleat Sculptor.
 

Videos:
Tips:
-I recommend Smooth-On Oomoo 30 for simple box molds
-I recommend Smooth-On Rebound 25 for brush on Molds. ALWAYS use sulfur-free oil clay or other sulfur free materials for your model with this product. If sulfur is in the environment, go with Smooth-On Mold Max Stroke or a polyurethane rubber such as Smooth-On Brush-On 40 or Polytek 74-30 mixed with Cabosil. 
-Note that Brush-On molds require a mother mold. This is usually made with burlap reinforced plaster or with Smooth-On Plasti-Paste.
-Always read through the technical bulletin (this is the directions for the product) before use.
-See Lifecasting and Metal pages for more information on these areas.
-Colorants (Smooth-On So-Strong) and Fillers (Pecan Dust, Marble Dust, Bronze Powder) can be added to your polyurethane casting. For clarity of color and filler try Smooth-On Color Match

Selected Artists that use this process: Liz Craft, Katharina Fritch, Jeff Koons, Tony Matelli, Allan McCollum Charles Ray, Kiki Smith, Rachel Whiteread

Katharina Fritch, Display Stand with Madonnas, 1989

Charles Ray, Oh! Charlie, 1992

Rachel Whiteread, House, 1993, concrete
Janine Antoni, Lick and Lather, 1993, chocolate and soap

Janine Antoni, Lick and Lather, 1993, chocolate and soap

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