Cold Casting using Polyurethane Resin and Metal Powders

If you want to create a mould and cast exact replica's of your original you will not need to create a splash mould and splash part - you can create your final and only mould straight away.

From the original toy we will be creating a bust piece (head and shoulders) so need to remove the arms and reposition the head. Then use filleting wax to plug any gaps like the one around the head and neck, this will stop any silicone leaking inside the toy.

Then create a mould box or use a ready made watertight container which allows for a 5-10mm gap all around the original, suspend the original from above using the tube and secure into place using the glue gun.

To create the Splash Mould: Weigh out and mix the silicone rubber and catalyst. Mix steadily to minimise air bubbles and scrape the sides and bottom of the pot until you reach a consistent colour. Then pour over the original and leave to cure for 24 hours. Once cured remove the mould box and using a zigzag cut to remove the original from the mould. Finally tape up the splash mould ready for casting.

To create the Splash Part: Weigh out equal amounts of Parts A and B of the Xencast® P2 Fast-Cast Resin according to the manufacturers instructions and mix steadily. This resin begins to cure within 2-3 minutes so remember to work quickly. Pour the resin into the mould, tipping and rolling so it gets into detailed areas, then leave to cure.

The cure time for this resin is 30 minutes, then demould the splash part and make any modifications like reshaping the base and shoulders.

Use filleting wax to add to the base shape if required, it will also secure the piece to the base of the container. Create a new mould box, then repeat the silicone process and pour the final mould and leave to cure for 24 hours.

Tape the final mould up ready for use and measure out a new batch of resin.

Measure out your choice of metal powder by volume rather than weight equal to two times the volume of Part A of the resin and mix together until all the powder is mixed in. The add Part B and mix again thoroughly and pour into the mould. Then leave to cure.

When you first remove the part from the mould you will see it is metal coloured but it's appearance is not metallic. You will need to abrade the surface to reveal the effect.

Use a sanding block and abrasive papers to finish the base, then use steel wool to abrade the piece all over. As soon as you start to rub with steel wool you will reveal the metallic effect.

To create extra effects you can use a spoon on the surface to burnish the piece. This will create highlights which look amazing. We also used black spray paint all over the piece and them rubbed off again with steel wool to leave the paint in the recesses, this gives great contrasting detail.