3D Printers are a tool we use to create master models and mold boxes quickly. By leveraging our print farm, we can take the same digital model of your piece and create variously sized and shaped products based on the same original work. An example is when you would like to offer multiple statuette sizes of a larger piece—one to adorn a desk and a larger size to be used as a room focal point. We can create both master models and molds to increase your offering.
3D Scanning takes an object from the physical world and brings it into a digital form that may be modified using software. We typically 3D Scan large objects such as sculptures and 3D print them as smaller-scale pieces, which we clean up, finish, and use as master models for our molds and castings.
Lifecasting allows for the creation of detailed body part reproductions. Traditional life casts use alginate or silicone and require the person to sit still for long periods. By leveraging 3D scanning technology, the person only needs to sit still for minutes. Once digitized, we can take care of the rest offline.
We use the master model for making molds to cast replicas. Master models are typically 1:1 model sculptures, or 3D printed and finished.
A matrix mold is made by creating an offset rigid shell around the master model. The void between the shell and master model is then filled with silicone to make the mold. The matrix mold is typically used as a mother mold so that the silicone won't distort during casting. They are also used to quickly replace or replicate the silicone mold to ramp up production.
The mother mold is a hard shell surrounding the silicone mold so that the silicone won't distort during casting.
Platinum Silicone is used to make molds of master models for reproduction. Certain Silicones may be used to make rubber prosthetics and props.
Polyurethane resin is a two-part resin used for casting. Part A and B are mixed and poured into the mold. The resin hardens into plastic to create the finished piece.
Polyurethane rubber is a two-part resin used for casting. Part A and B are mixed and poured into the mold. The resin hardens into rubber to create the finished piece.
Reusable Master Mold
Silicone molds don't last forever, so for popular castings, we often create a reusable master mold that we use to quickly replace worn-out molds and mass produce molds to ramp up production castings.
Rotational Casting (aka Roto Casting)
Rotational casting is a process for creating hollow models. This process saves on materials, thus reducing the overall cost of producing larger pieces.
Slush Casting ( aka Slosh Casting)
Similar to rotational casting, except usually done by hand on an open face mold. The slush cast piece may be backed with foam or another material to provide rigidity and strength.