Ken Salisbury
05-03-2005, 4:55 AM
My nephew visited me several weeks ago from PA. While in my shop he noticed my laser engraved wooden signature medallions. He asked how much I had to pay for them and said why don't you make a mold and cast some from colored plastic. The reproduction cost would be much less and you could make as many as you want when you want em.
Now since David is the President of Polytek Development Corp (http://www.polytek.com) which specializes in liquid mold rubbers and casting plastics I figured he must know what he is talking about.
He took 2 of my cherry medallions back to PA with him. A week later I received a package containing a rubber mold, some samples from the mold, liquid rubber molding material, plastic casting material, release agent and a few dyes to color plastics prior to molding.
The very very flexible rubber mold for 1¼" and 1½" medallions:
http://www.oldrebelworkshop.com/crafts/medallionmold.jpg
On the left is the 2 cherry medallions the mold was made from. The right 2 are molded medallions which were wipped with shoe polish (1 black/1 brown) to highlight the details. To my surprise, the molded ones revealed much morre detail than I expected. You can actually see some defects in the wooden master revealed in the molded one. The bottom one is actually a plain white plastic one (you can't see the engraving in the pic - but take my word for it - it's there)
http://www.oldrebelworkshop.com/crafts/medallion.jpg
This close up shows the defects transferred from the wooden medallions to the casted ones. I was amazed at the finite details of the casted items.
http://www.oldrebelworkshop.com/crafts/medallion2.jpg
I plan on getting Keith :D to laser engrave some "masters" from something like aluminum or corian, etc void of surface defects so I can make multple cavity molds and pour colored plastic to make wood-like medallions.
I believe I can improve on the process and produce a very nice "Signature Medallion"
Please do not ask what the material costs are because I don't really know since my materials were free gratis from my nephew :D Once I perfect the process I will do a cost analysis and report that to you.
If this process works out like I think it will I have already imagined some other applications.
The experiment will continue when I return from the Swap Meet
Now since David is the President of Polytek Development Corp (http://www.polytek.com) which specializes in liquid mold rubbers and casting plastics I figured he must know what he is talking about.
He took 2 of my cherry medallions back to PA with him. A week later I received a package containing a rubber mold, some samples from the mold, liquid rubber molding material, plastic casting material, release agent and a few dyes to color plastics prior to molding.
The very very flexible rubber mold for 1¼" and 1½" medallions:
http://www.oldrebelworkshop.com/crafts/medallionmold.jpg
On the left is the 2 cherry medallions the mold was made from. The right 2 are molded medallions which were wipped with shoe polish (1 black/1 brown) to highlight the details. To my surprise, the molded ones revealed much morre detail than I expected. You can actually see some defects in the wooden master revealed in the molded one. The bottom one is actually a plain white plastic one (you can't see the engraving in the pic - but take my word for it - it's there)
http://www.oldrebelworkshop.com/crafts/medallion.jpg
This close up shows the defects transferred from the wooden medallions to the casted ones. I was amazed at the finite details of the casted items.
http://www.oldrebelworkshop.com/crafts/medallion2.jpg
I plan on getting Keith :D to laser engrave some "masters" from something like aluminum or corian, etc void of surface defects so I can make multple cavity molds and pour colored plastic to make wood-like medallions.
I believe I can improve on the process and produce a very nice "Signature Medallion"
Please do not ask what the material costs are because I don't really know since my materials were free gratis from my nephew :D Once I perfect the process I will do a cost analysis and report that to you.
If this process works out like I think it will I have already imagined some other applications.
The experiment will continue when I return from the Swap Meet