Backdating Mold Making and Casting

Posted by EnvironMolds , Labels: , , , , , , Tuesday, June 9, 2020 12:10 AM

The techniques of mold making and casting are nothing new. In fact, they emerged way back in the Neolithic times and gradually developed as the key for making most of the objects we use and enjoy today.

Mold making and casting procedures are used to make most of the things we use – from household goods and decorative items to industrial equipment and structural components. These techniques are especially popular in the world of art and design and are patronized by artists of various genres. They are commonly used for new artworks, art reproductions, sculpture making, ceramic works, garden statuary, candle making, props, masks and the like. The same are also applied for architectural restoration works, prototype tooling, taxidermy, fossil preservation, etc.



Not to mention the beautiful art of life casting. Indeed, life casts have emerged as a magnificent mode of creating a three-dimensional reproduction of the live human body. The regular techniques of making molds and casts are used with appropriate skin-safe materials to make body molds and life casts of the face, hands, feet, belly, torso or even the entire body. These are extremely popular for infants, friends, families, pregnant mothers and more. The same is also used for medical prosthetics, special effects, animatronics, etc.


The synthetic materials like polyurethane resin, latex rubber and silicone rubber may be new additions to the fold, but mold making and casting themselves are not contemporary techniques by a long shot. In fact, they date back to the prehistoric times when settlements were being established and agriculture came into being. The primitives slowly developed these processes to fabricate tools, equipment, jewelry and religious artifacts What’s more, the oldest surviving casting of a copper frog dates back to 3200 BC!

With the passage of time, these techniques were applied for making and reproducing artworks, especially sculptures. The introduction of hollow wax casting was the precursor to the highly prized Greek statues and Roman copies made later.

Clay and plaster continued to be the popular medium of making molds and casts down the ages. Gradually, art schools started teaching mold making and casting and used wood or terracotta also to make the molds. This led to the creation of iconic artworks that remain illustrious till date. Simultaneously, they were used for making pottery and ceramics as well.

These age-old processes finally made their way from the homes of royals, aristocrats and art aficionados to the foundries of today. The advent of industrialization witnessed a quick adoption for the mass production of regular objects in a range of styles. Injection molding was introduced in industries and new materials like plastics and polymers also came into being. Everyday items became inexpensive due to lower costs of production.



These techniques were progressively incorporated into the making of complicated automotive parts, equipment, machinery and even structures.

Indeed, from the simple molds and casts of ancient times to two part molds and cold casting for artworks to highly technical and complex processes in industries - mold making and casting have surely come a long way!

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Life Casting The Feet

Posted by EnvironMolds , Labels: , , , , , Wednesday, May 27, 2020 6:53 PM

A life cast is always a treasured keepsake. While hands and face are the common body parts favored for a life cast, recreating the feet also makes for a novel souvenir. Making it is a wonderful experience too!

Hands make beautiful life castings. They are very popular for commemorating special occasions, marking the birth of a baby or just celebrating with friends. The possibilities are endless – people try out different ideas - like a couple holding hands together, a rings of hands with friends, parents encircling the hands of a newborn child, a person holding a golf ball, a baseball glove or a trophy and so on.

These life castings can be made in plaster or even cold cast in metal or stone. They are finished with a brass name plate to mark the name, occasion and other details.


However, it’s not just the hands, even the feet have many a story to tell – a step, a movement or even just the position. A life cast of a foot is a complex creation that looks interesting due to the three-dimensional composition. Parents love to get a life cast of their newborn’s feet and even encircle the feet with their own hands to signify the inherent love, care and protection. The casts look beautiful and can be treasured forever.

Making a mold of the foot and then a life cast is also quite a challenge in itself. The leg is usually encased in a batch of alginate mixture. Deciding the pose and angle is important here. The model should feel comfortable while the foot is dipped in alginate. Care is also required as the drying alginate may tend to crack with the body weight itself.

In fact, foot molds are usually made in two parts as it is difficult to extract the leg from the alginate mold once it has set. Even if the life casting artist tries to make a cut to separate the leg from the alginate, the mold may be rendered useless. Making it in two parts is better with proper keys for the registration of the parts and sprue holes for releasing the trapped air.

The foot mold has to capture very many details right from the toes and nails to the folds in the skin, the indentations and even the tiny lines per se. In fact, the mold will also recreate the cracks in the soles of the feet et al. These have to be finished properly prior to the final casting to avoid reproducing them in the cast!

Often artists use trial and error to work out the best method of making the mold from the body. This calls for patience and foresight while making the body molds again and again.

Finally, the life cast of the feet, or any other body part or even the entire body should be finished with name plates engraved with the title, artist name and other details. This will give a professional, gallery finish to the life cast and add to the experience as well!

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Getting to Know FiberGel Alginate

Posted by EnvironMolds , Labels: , , , , , Saturday, May 9, 2020 4:48 PM

FiberGel alginate is a unique patented alginate formula that is quite strong and resistant to tears. Yet, it sets soft and has delayed shrinkage which makes it perfect for special effect works.

The simple alginate powder that was initially used for making dental impressions has slowly evolved over the years into a valuable concoction for making life casts.

The beauty of alginate powder is that being a natural substance, it is completely safe for the skin. However, regular alginate has a quick setting time and is prone to tearing as well.

Various manufacturers try to play around with the formulation to slow the setting time on the one hand and increase the tear resistance on the other. They also try to manipulate other characteristics - like hardness/softness of the alginate once it sets – to suit specific applications.

Accordingly, different groups of alginate are available in art stores today. Apart from the regular life casting formulae that are characterized by a firm set and high strength, there are special formulations with a soft set (suitable for use on babies).


The famed art supplier, EnvironMolds has launched a unique alginate formula called FiberGel E F/X Grade alginate. This is fortified with special fibers that considerably increase the adhesion, strength and tear resistance properties of the alginate. In fact, it is independently tested 40% stronger than the leading brands.

This alginate formulation is thixothropic and will stay in place without dipping or running off like regular alginate mixtures. Moreover, the fiber matrix enables the alginate to retain moisture and reduces the shrinkage rate manifold. Therefore, the alginate mold stays soft and flexible and boasts of delayed casting time as well. Yet, despite the fiber content, the alginate mix still manages to yield the same creamy smoothness that is characteristic of regular alginate formulae.

During studio use, artists find that the mixing and consistency of FiberGel alginate is just like regular alginate. It can easily be applied in a smooth and uniform manner and will continue to stay in place without running. The mold will set within 5 to 6 minutes and does not necessarily require a shell mold either. When demolded, the alginate mold comes off easily in one piece without pulling itself apart. Even bigger body molds will not tear when removed in spite of the larger area or even undercuts. And as the mold will not shrink soon, the cast will turn out closer to the original size without losing any detail.

This is why FiberGel alginate is considered ideal for professional high-production, high-end detailed E F/X work. It can easily be used for creating different kinds of special effects on the sets of movies and television shoots. As the alginate mixture does not run or drip, it can even be applied on vertical structures to capture molds. The comparatively thicker mix of the alginate ensures that it will continue to stay as applied and will recreate all the surface details of the structure as it is!

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Making Latex Molds and Casts

Posted by EnvironMolds , Labels: , , , , , Thursday, April 23, 2020 4:30 PM

Latex rubber is a popular choice for making both molds and casts. Latex has several useful properties and it is also relatively easy to make both latex molds and casts by following the right procedures.

Liquid latex rubber is a versatiles material that is considered tough, durable and economical as well. It lends itself well for various applications in the fields of mold making and casting.

Latex molds capture details well and are usually used to make plaster and resin casts. They are also handy for casting abrasive materials like concrete as the mold will not tear despite the coarseness. The latex can also be applied on architectural details on the walls or even ceilings without the latex running off. This works especially well for making molds for restoration works.

Latex casting is usually used for making hollow molded rubber articles, toys, balls, imitation pottery, display items and flexible props. Liquid latex is popularly used for mask making as well as special effects works like wrinkles, scars and gashes for theatre, television and films. It is even commonly used as an adhesive for bald caps.

Apart from this, latex is useful for slushing casting clays for ceramic works and for coating polystyrene and other fabrics and even tools. This forms a protective and water proof coating on the items. It even allows for better handling and insulation for the tools.

How to do?

It is easy to use latex rubber for making molds and casts. The most common method is dipping for mold making and pouring for casting - No elaborate process or expensive molds are required.

Latex molds are created by dipping the model directly into the latex rubber itself. Simply dip the model into the container to get a uniform coating and then let it dry. Repeat the procedure 10 to 12 times to build up the adequate thickness. Alternatively, the latex can also be painted on the model multiple times, while allowing each subsequent coat to dry properly.

The procedure for making latex casts is also quite similar. Here, the latex rubber is poured into the mold and allowed to sit for some time. Then the rubber is poured out again. A thin film gets deposited on the inner side of the mold and will dry to form a flexible cast. Keeping the latex inside for a longer time or repeating the procedure will increase the thickness of the latex cast.

Usually plaster molds are preferred for making latex castings. This is because the porous plaster will absorb the water in the latex and allow it to cure to form a cast. Therefore, latex and other molds are generally not preferred for latex casts.

Demolding liquid latex molds and casts is also simple as they can be easily peeled off the model or mold. However, it is advisable to dust the latex surface with talcum powder before demolding, else the latex will stick to itself. Latex casts can be painted with special latex paints to get the desired finish.

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Sodium Silicate Deflocculates Clay Slips

Posted by EnvironMolds , Labels: , , , , Friday, April 17, 2020 5:05 PM

Slip casting is a common technique used for the mass production of complicated ceramic items. It is made by mixing dry clay with water along with an effective deflocculant like sodium silicate.

Pottery is the common method used to make pots, dishes and other items using clay or other ceramic materials. The potter fashions the piece on the wheel with his hands and it is then fired to give it a hard and durable form. However, there is another technique for making hollow ceramic and porcelain articles in complex shapes that cannot be fashioned on a potter’s wheel. This is known as slip casting of clay, usually along with sodium silicate.


Slip casting is a simple technique of pouring thinned clay into a mold. The mold is filled to the brim and the clay is allowed to settle inside. This allows the slip to build a thin layer inside the mold after which the excess material is drained out. The amount of time the clay slip stays inside the mold will dictate the thickness of the cast.

The clay is allowed to cure and demolded once it starts to separate from the sides of the mold. Usually, slip casting is done in plaster molds as the porous plaster will absorb the water from the slip and allow for quick casting.

When it comes to making the slip for casting, people usually assume that it is done by mixing clay with water. However, this requires a lot of water which in turn will take a long time to shrink and dry. Moreover, the clay may not disperse properly in the slip and will settle at the bottom of the mixture. This is why a deflocculant like water glass (chemical name – sodium silicate) is mixed with the clay before adding water. This will thin the clay or reduce its viscosity by dispersing its particles and thus require much less water. But it should be kept in mind that excess sodium silicate will have an opposite effect and will actually make the clay thicker or flocculate it!

Top quality liquid sodium silicate can be sourced from EnvironMolds at Artmolds.com.

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Getting to Know KastEZ Polyurethane Resin

Posted by EnvironMolds , Labels: , , , , , Sunday, March 29, 2020 9:25 PM

There are various kinds of resins and each type comes in different formulations. KastEZ is a popular polyurethane resin formula that is commonly preferred by artists for their casting works.

Resins come in different types – polyester, epoxy and polyurethanes are the commonly used ones for making castings.

Of these, polyester resin is considered the most easy to use and the price is also reasonable. It cures to a hard form too. However, it emits noxious fumes which are quite dangerous for the user. Epoxy resin is also considered easy to use and is advised for beginners, primarily because of the longer pot time. It is safe to use, but cures soft which can make it difficult to handle.

It goes without saying that polyurethane resin is the most popular resin, even despite the comparatively higher price.

What works for polyurethane resin is that it is versatile and boasts of excellent strength, durability, elasticity and resistance to oils and other chemicals. It captures details well and generally cures to a hard form. However, varying the formulation of the resin can yield varying properties from a soft pliable rubber to a very hard and rigid plastic. It comes in both opaque and water clear forms to suit different applications. The resin is commonly preferred for general mold making and casting. Some of the polyurethanes may require the use of a respirator due to a mildly noxious odor.

The EnvironMolds MoldQuik is an example of a pliable polyurethane whereas KastEZ Resin cures to form an opaque, hard plastic casting.
The latter is a two-part polyurethane casting resin used in 1 to 1 ratio by volume. It is available in 16 oz, 2 quarts and 2 gallons packaging. Initially, when both the catalyst and base are added together, the resin will look cloudy. It will begin to clear with the mixing. A thorough mixing while properly scraping the sides and bottom will cause the resin to become clear and this is when it is ready to use.

KastEZ resin is easy to use. Simply pour the resin into the mold and allow it to set. It cures at room temperature – within 10 minutes itself. A release agent is required, but demolding is a straightforward process as well.

The cast will be lightweight and will form a hard plastic with an ivory white color. Special resin dyes have to be used to impart a specific color to the resin. The colorant can be easily mixed into the resin to get the desired color. Proper mixing will give a uniform color while a few strokes will create a marbleized effect. The dye will not affect the pot life, demold time or even the inherent properties of the cured plastic in any manner.

This same resin can in fact be cast in both rigid and flexible molds. Some of the most common uses are figurines, displays, rapid prototypes, special effects and sculpture reproductions. In fact, KastEZ polyurethane resin is the right choice for almost any application.

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The Many Uses and Forms of Plaster

Posted by EnvironMolds , Labels: , , , , , Friday, March 13, 2020 2:14 AM

Plaster is a simple powder that can be made in various forms and used for different purposes. The usage varies from smoothening walls and ceilings to decorating them to make castings of art works.

Plaster is a commonly used material that enjoys varied uses. The most common usage is in construction to give a smooth surface to coarse walls and ceilings. There are various kinds of plaster – like cement, lime and gypsum or even clay. Plaster is basically a dry powder with one of the above materials being used as a binder. It is mixed with water to form a workable paste. It slowly solidifies on exposure to air to form a hard and stiff covering on the external or internal walls.
Apart from this, plaster is also used to make false ceilings and in decorative architecture. Complex shapes and carvings can be created on walls and ceilings using plaster of Paris. This is basically gypsum deposits mined in Paris, and hence the name.

Plaster enjoys great patronage in the art world too. It can be used to replicate art works and make casts using quality products like CastRite Art Casting Stone. Art plaster is a special type of plaster – regular plaster cannot be used for casting as it does not hold details well and will also tend to become chalky and flaky over time. Moreover, it is hydroscopic in nature and will turn into an irreversible solid form on the slightest exposure to moisture.

Casting calls for a hard casting plaster that can capture the fine details from the mold and set fairly quickly. Yet, it will allow carving and tooling as needed. What’s more, this type of plaster can also be used to make molds.

Plaster can be cast into various mold materials like clay, alginate, rubber, cement, wood, etc. However, care should be taken as the chemical reaction of plaster with water tends to release heat. This is why plaster is not usually used directly on the skin. Plaster infused bandages are a good option for making basic body molds and shell molds.

CastRite Art Casting Stone can be easily sourced from the EnvironMolds website, Artmolds.com.

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