Hang ‘em high
We built these molds to fabricate vacuum formed hanging elements representing the Aurora Borealis. Once painted they were suspended 50-feet above a mall ice skating rink in Moscow, Russia.
Repetitive but not boring
Our vacuum form machine molds flat plastic by clamping it into a frame and heating it until soft and pliable. It is then lowered over a mold, and any air trapped between the plastic and the mold is sucked out with a vacuum pump. Once cooled the plastic becomes rigid again and can be trimmed.
Do you know why muffins always look like muffins? Because they’re made with molds. We’ve made some pretty weird muffins: Willy Wonka’s head, 12-foot leaves, Star Wars Battle Droids, Brent's hands, and squid medallions.
We don't just make the muffins.
In the mold shop, we also make the pans. Ingredients: Silicone rubber, fiberglass (high in fiber), urethane foam, vinyl ester resin, plaster (loaded with calcium), cast aluminum, polyester resin, ABS, PVC, ABC, 123, ASAP. Salt to taste.
Sweeet! - These oversized pieces of candy were used as decorative elements in a fancy private residential theater.
Imagine the dental bills.
The lollipop is made with translucent resin. Don't you want to lick it? Go ahead. Lick it.
Impressionists - Not only are these plastic replicas of William Morris glass accessories we made for Donna Karan more durable than the originals. We made hundreds sold worldwide.
One, two, buckle my… dress
Their light weight assures that the runway models won’t collapse under the heavy load. Hey, it could happen. Have you ever seen one of those girls up close?
Olio como va? - These 7-foot tall vessels were inspired by ancient Mediterranean terra cotta oil jars, and were used in an Italian restaurant at the Wynn Casino in Macau. We made fiberglass molds from a foam original turned on our foam lathe and then cast fiberglass jars.
The texture and paint transform them into a convincing ancient terra cotta.
Sitting on his glass - This silicone mold is used to create large panels of faux glass. We utilize a special machine that mixes the material as it's pumped into the mold, and minimizes the amount of bubbles that might get in the resin.
Cast of hundreds
For this project, the client originally wanted to make these panels with real glass, but cost, weight and liability prevented using traditional methods and materials.
We are not worthy - We fabricated a 6-pack of these 8-ft tall interactive beer bottle kiosks beginning with a hand-sculpted form from which molds were made.
That's not what she said...
The trickiest part was getting the vinyl graphic covering to conform to the client's high standards for brand recognition. Long story short - the client was thrilled.
Faux Paleontologists - This Pterodactyl head was cast in fiberglass from a silicone mold. The silicone forms to the original sculpture with such accuracy, the skin texture is lifelike.
A lasting impression
The more information you can provide to us, the easier it is to determine the appropriate method and material. But please, remember our corporate tagline: "Just because it's plastic, doesn't mean it's cheap."
Not so tiny bubbles - These integrally colored spheres are cast directly onto strands of bead chain on our amazing roto-cast machine, and then hung from a custom metal frame, festooned with low voltage lights.
The end result is dozens of 4-foot tall chandeliers made for the AWARD WINNING “Savvy" Department at Nordstrom stores nationwide. Needless to say, we consider ourselves pretty good problem solvers, if we do say so ourselves.
Copy Cats - Donna Karan worked with the glass artist William Morris to design accessories for her new fall line. Donna Karan International came to us to make lighter replicas that were more durable.
We Kick Glass!™
Provided everyone’s lawyers are happy, the nice thing about copying is that you’re given a second chance to improve the durability of the original. We cast hundreds of parts with a translucent, integrally tinted resin.
Roto-CASTER - We strap a silicone rubber mold to this machine, and the entire room spins around it! (When in use, our employees find it creates a difficult work environment.)
Are you dizzy?
Actually, this Rube Goldberg-looking contraption is a rotational casting machine that rotates a mold, and allows us to make multiples of items that are hollow, lightweight, and relatively seamless.
Creative genius - We create an impression of an object that needs to be replicated, using plaster, latex, epoxy, fiberglass, urethane, or some other material. Then we use the impression, or mold, to generate anywhere from one to one-hundred or more exact duplicates of that object.
It’s all very scientific
We have the ability to make molds from different materials and produce parts from different materials including plaster, rubber, fiberglass, epoxy, urethane, concrete, foam and all kinds of plastics. It just depends on how the piece will be used. Our experts will figure it out.
Mold…not fungus - We cast these cell phone display fixtures out of a flexible translucent tinted silicone rubber. One mold can generate anywhere from one to one hundred or more exact duplicates.
but rather, three-dimensional template making.
When a liquid material, such as rubber or resin, is mixed with a catalyst, air bubbles can enter the material. By putting the liquid material into our vacuum chamber, all of the air bubbles are sucked out to prevent air holes or imperfections from occurring in the final product.