Manufacture
Most of our Master patterns are produced in house, but can be outsourced as 3D printouts or engineered components. Master patterns can of course be supplied to us by the customer but will need to be 6% or 3% larger than required depending on the production method chosen.
The Master pattern is used to make a Master mould in silicone and this rubber mould produces the production patterns. In turn rubber moulds from these produce the final production castings.
Mould making
All mould making is done at Custom Cast as the mould design is critical to ensuring the optimum production standards. Mould life will vary depending on a number of factors through the production process but the moulds are replaced at intervals when it becomes necessary to maintain quality and improve dimensional stability.
All of our production is bespoke in nature and entirely hand crafted to order by our small team of craftspeople. It therefore follows that there may be some natural variations in exact dimensions and colour of finish.
Finishing
Polyester resin is a very versatile material which is hand cast into silicone rubber moulds to produce a wide range of sizes and shapes. We are able to reproduce a wide variety of textured and coloured natural surfaces including wood grain of many types, stone, leather, fabric and even fruit and food textures. These effects are largely achieved with staining techniques but we can also add sprayed surfaces, usually polyurethane based, in a full range of colours.
The resin itself can also be coloured if desired using coloured pigments and a range of natural and mineral filler powders. Customers can also receive their castings plain and unfinished ready for them to apply their own finish.
