Finally, i get to share with you how I designed and made the most challenging mold I was commissioned to make by Concrete Etc. We are talking about a massive mold - 500x500x350mm. Here is the model itself :
Credit: Model design by Concrete Etc
OK, OK… it is actually the first cast of the mold, but since I forgot to take a picture of the model this will do. Either way this is more about how I made the mold. Nevertheless you have to admit that the shape is simply stunning.
We have to begin with the design of the mold itself. A requirement was a perfect seamless finish and a long lasting mold. Which basically left me with only one chose - thin silicone seamless sleeve mold with a hard supporting shell. And since I wanted to keep the mold on the light side decided to make a fiberglass shell, which also made assembling the mold quick and easy.
Here is a good place to note that the planter/coffee table is available at the Concrete Etc online shop - www.concreteetc.co.uk and also at the upcoming
Midcentury Modern show
Dulwich, Sunday
17th November 2019 - 10am - 4pm.
Tickets are available at
www.modernshows.com/shows/
You’ll have a chance to see this gorgeous looking concrete piece and of course the chance to make it your own.
The next step was to actually start making the mold. I decided to apply the silicone rubber by brushing it directly onto the model in layers - really unconventional technique for this material, but the complexity - number of overhangs and angled planes.
This was a long and stressful process as the silicone rubber is not really meant to be used this way and I had to make sure to apply even coats every single time. So, over the course of a week I was able to make the silicone sleeve. The next step was to make a fiberglass shell to support the rubber. Again, this being the world’s most complicated shape - this was not as straight forward as it sounds. The shell had to be made in sections.
So, as you can see I divided the sections with acetate sheets and it was to *fiberglass.
Fiberglass is a type of fiber-reinforced plastic. To achieve it’s strength and light weight the randomly arranged and flattened into a sheet fibers are being soaked in epoxy or as most of you know it as thermosetting polymer matrix. It is being applied on layer.
The next step was to make holes for the bolts that will allow the shell to be assembled and held together firmly. And as we all know - You can never have enough clamps.
Aaaand here it is! The story of the world's most complicated concrete shape and the creation of it’s mold.
Now, don’t get me wrong I LOVE making molds and I make them good, but it’s all about what you pour in the mold…
