Académique Documents
Professionnel Documents
Culture Documents
2003 - Volume 1
www.smooth-on.com
Simply Smashing!
ces
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Of G Pag
into the guiness book of world records with this scene from
the latest James Bond Movie . . . Page 3
impossible . . .
DragonSkin
Page 6
PoYo Putty
Goes To
Ground Zero
Page 7
EZ Spray System
Pour-It On
Spray-It On Brush-It On
Apply By Hand
Smooth-On Has
Harder
Brush-On 40
Brush-On 50
Brush-On 60
tm
tm
tm
Holds a vertical or
inverted surface
better than any other
mold rubber, yet
reproduces very fine
detail. Molds are
incredibly strong and
are great for production casting of Matrix, gypsum, concrete,etc.
Used by restoration pros around the world!
YO
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tm
Max
d
l
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nes
Silico
New Mold Max Silicones (10A - 40A) feature high tear strength
and are great for production casting of resins, plasters, etc.
Above: Reproducing 300+ year old frame with soft Mold Max 10.
Casting made from Matrix NEO. Perfect Detail Reproduction!
www.smooth-on.com
Fax. (610) 252-6200 * Easton, PA. 18042 USA
Glass Take
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to take place in an ic
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UK clim
orate A Real Breakthrough - James Bonds car smashes through ice
eating the films elab
task of somehow cr
own
palace doors in Die Another Day. SMASH! Plastic made this and
ted effects using kn
ice palace and rela
other spectacular scenes in the film possible. This scene was a
.
record-breaker; for details, visit www.guinnessrecords.com
material technologies
Die Another Day 2002 Damjaq, United Artists Corporation. All rights reserved.
This being a James Bond film however, meant that elements would be smashed to pieces on a grand scale in
the 007 tradition. Using conventional breakaway plastic products for such scenes could have posed a
problem because they are difficult to work with. Needing to be heated to 350F/176C in order to use them,
the working time on these products is short and unpredictable. In addition, the odor is horrific and handling
cured pieces results in a high breakage / waste factor.
Enter SMASH!
SMASH! Plastic It was about that time that
SMASH! Plastic breakaway
glass made its way onto the
special effects scene, and Bond
effects artisans put it to
immediate use. SMASH! is
easy to use and cures at room
temperature. It has no odor,
offers a good working time and No Hassle SMASH! Plastic Effects cured elements are easier to
Easy to mix and pour, cures to a water
clear plastic that smashes like glass.
handle.
Cured
material
looks
A SMASH! Plastic window pane shatters as it
and breaks just like glass and is
should, and the subject remains unharmed.
Great for making bottles, panes, vases, etc.
used to make window panes,
Follow directions carefully before using.
bottles & other glass/ice effects.
It is easily color tinted or pigmented with SO-Strong tints.
In total, over six tons of SMASH! were used to create the smashing
ice effects for this Bond film, including a record-breaking scene where 007
drives his Aston-Martin Vanquish through the huge ice palace doors.
Whats Next? SMASH! was used (or is being used) for such films as
Tomorrow Is Another Day (Canada), X-Men II and Harry Potter III
Rubber Glass is easy to use and
(U.K.), Terminator III (Hollywood) and Barkari Bakash (India).
crumbles to look like broken glass or ice.
Broadway shows using SMASH! for each performance include Stomp Use to finish the effect of an actor going
through a window - they land on the
and The Goat.
ground and roll in Rubber Glass
Finishing The Ef fect W ith Rubber Glass - Over 1.5 tons of
Rubber Glass were used in Die Another Day. Any time you see an actor in proximity to glass, it is in fact
Rubber Glass that is being used to create the effect. Rubber Glass was first used in the Star Trek: The Next
Generation series and has been used in films like Godzilla, The Matrix, Spider Man and in commercials
for Coke and Budweiser Beer. Mix two liquids in equal amounts and let cure to a soft, water clear rubber. It is
then easy to crumble and use for any glass or ice effect.
Bon-Apetit - FlexFoam-iT! V
perfectly pigmented & textured to
look like bread. Used in the picnic
scene in Oklahoma. Below:
FlexFoam-iT! Plate of Lo Mein
used in Flower Drum Song.
www.prismprops.com
What Are Your Options? Mann Release Agents offers two products made
specifically for releasing foams from most surfaces. Ease Release 1700 is a
convenient aerosol that is easy to apply. Make sure you spray onto your mold surface, brush
the release agent over all surfaces that will contact the foam and follow with
another spray application. Ease Release 2831 comes in liquid form and can be applied
with a brush. Both will release your foam castings with out collapsing the foam or affecting
surface detail. Get More Life From Your Molds - Production casting of foams will also
burn out silicone or urethane molds relatively quickly. Using ER 1700 or ER 2831 will
significantly extend the production life of your molds. For your nearest Mann Release Agents
distributor, visit www.moldreleases.com
4
I am constantly
approached by material
suppliers to try their latest,
greatest me-too product
and always end up using
Smooth-On. I cant afford to
take chances and need the
best materials that I can get
my hands on. They must
work the same every time
with no surprises.
-Guy Louis XVI
Ready . . .
Dragon Skin
Set . . .
Dragon Skin is a very soft, incredibly strong silicone rubber that is used to make skins for animatronic
movie & theme park creatures. It will stretch many times its original size and rebound to its original shape great for repetitive motion applications. Dragon Skin & Dragon Skin Q (faster cure version) - with a 1A:1B
by volume mix ratio, they are easy to use and cure quickly to a water-translucent rubber. Dragon Skin
really resists wear and tear, and is also used for orthotic and orthopedic applications. And, of course, you
can make soft, long-lasting molds with Dragon Skin - poured or brushed on.
Limitless Color Possibilities . . . Add Silc-Pig color pigments to
Dragon Skin to make a paint that will adhere to cured Dragon Skin . Your
colored Dragon Skin creation will bend & flex with no sign of peeling or
cracking. Great for repetitive motion animatronics, colormatch orthotics, etc.
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Be T he P oYo - H ow T o M ix & A pply - People who have discovered PoYo Putty love its no-mess
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convenience and on-the-spot usability. But PoYo can be tricky to mix and apply until you get used to it.
Here are a few tips to help you make your own PoYo molds.
Quick - Go Mold A Tree!
tm
tm
An Exact
Reproduction!
PoYotm
was mixed
& applied
to capture
tree bark
detail without any
surface
prep.
Mold was
removed in
30 minutes.
SC 320
resin with
black pigment gave
a perfect
bark copy.
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Low
Since introducing Mold Max
tin cure
silicones, they have been selling as fast as
we can make them.
Available in Shore 10A, 20A, 30A and 40A, Mold Max offers users a silicone value; good physical properties, good chemical resistance and high-tear strength at a good price. Weve also been told that, unlike other
silicones, they are also consistent from batch to batch - you know what you are going to get every time you
use them. Mold Max silicones are used around the world for casting waxes (low and high temperature)
low melt temperature metal alloys, resins (polyester, urethane & epoxy), plasters, concrete, soap, etc.
tm
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Lowering The Viscosity For Faster Vacuuming & Easier Pouring Mold Max 30 with Thi-Vex thickener
-Add Our Silicone Thinner used to make a brush-on silicone mold
Pouring Over Sulfur-Clay - Mold Max 30 With Safire Catalyst
of this complicated model.
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Applications -
Without
Matrix-Ctm
With
Matrix-Ctm
1. The fourth
plinth
pedestal
featured
The Tree Of
Knowledge
sculpture
prior to Ms.
Whitereads
creation
being
installed.
Her vision:
an inverted
plinth cast in
clear resin.
2
2. Artist, Rachel Whiteread, stands near the
maquette mold used to make test castings prior
to the big pour.
Ms. Whitereads vision for the Fourth Plinth was to offer a pause - a
quiet moment in the bustle of central London by creating an inverse
representation of the plinth itself, cast in a water clear see-through
plastic.
Largest Resin Object Ever Made - with Ms. Whiteread aiming for an
entry in the Guinness Book Of Records, the final casting was to be
over 12 tons of resin. This posed a considerable problem in that
existing resin formulations of this type gave off a tremendous amount
of heat during the curing process, which meant that there was a risk
of such a large casting cracking and/or distorting.
Dimensions Of Final
Assembled Casting:
16 L x 8W x 16H
(4.8m x 2.43m x 4.8m)
Weight: 24,680 lbs.
11,195 kgs.
10
4
4. One of Smooth-Ons vessels (10,000 lb.
capacity or 4,536 kgs.) made the trip across the
Atlantic for just this pour. Crystal Clear resin
(Parts A & B) was pumped from drums into the
mixing vessel where it was mixed and vacuumed
prior to being dispensed into the mold cavities.
Doing What Has Never Been Done Before - The Reality Sets In
Ms. Whiteread states that, I think it is remarkable that we have done it,
got this far. Im totally amazed we have achieved the engineering possible to make this volume of material work. And we ran out of material
and had to have it shipped from America. They (Smooth-On) manufactured it and got it to us very quickly. I couldnt ask for more.
5. Revealing Moment - Rachel Whitereads face
Quotes take from an article published in The Independent, May 2001
Very Clearly,
A Pause . . . A
Quite Moment in
the bustle of
Central London .
Monument is
an inverse
representation of
the plinth pedastal
upon which it
rests.
6
6. Peter Turnock of Bentley Chemical gives
thumbs up next to newly demolded castings.
7. The unveiling of Monument in Trafalgar
Square drew the curious, the critical, celebrities
and sculpture admirers from all over the world.
11
Crystal Clear Resins (CC200, 202, 204, 206) have been used for years to create water-clear sculpture
castings (see The Plinth, previous page). But these resins are also used to make prototypes and industrial
design / display castings all over the world.
A recent Crystal Clear industrial application
involved Ford Motor Companys restoration of The
Red Buses Of Glacier Park in Montana. The fleet
of 33 buses, originally built in 1930 to transport
tourists through Glacier Park, fell into a state of
disrepair and was retired in
Above: Veterinarian
1999. Ford contracted TDM
training aid. Middle:
Encapsulated key for
Company (Livonia, MI) to do
New
York City store window display made by
the work and they used
Rocca & Noto (New York) Right: Kartel Spa
Crystal Clear plastic to make (Italy) makes Crystal Clear tables.
replacement lenses and
corner lights for the buses.
Allen Millisor of TDM used
Crystal Clear resin and
Mold Maxtm silicone rubber to
Allen Millisor shows off cast the pieces stating that,
these materials helped us
his Crystal Clear
lenses cast from Mold avoid expensive tooling on the
Max 30 molds.
project.
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We have recently had requests for a harder version vs. our existing clear products that also offered a higher
heat distortion temperature for prototyping and other applications. Crystal Clear 220 is a harder addition to
the Crystal Clear line (Shore 85D vs. 80D) and heat curing / post curing is recommended.
Like our other Crystal Clear products, CC 220 is UV resistant. Because this is a
heat cure product, the heat resistance of finished castings is higher (heat distortion
temperature of (212F / 100C).
Because it is harder, it is easier to precisely machine and polish (remove scratches).
You also get less suck back and shrinkage with this product vs. other clear
products. Casting thickness maximum is about 4 cubic inches (65 cm3). The mix
ratio is 100A:75B by weight. Vacuum degassing or pressure casting to eliminate
bubbles is recommended. As with our other Crystal Clear products, silicone molds
(Mold Max silicones work well) must
be thoroughly cured before casting
Crystal Clear to avoid cure inhibition.
Like all aliphatic resins, proper ventilaOliveras Lighting Co. in
tion and a NIOSH approved respirator
Chihuahua, Mexico,
is recommended when using.
supplies hotels and
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12
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Christov Curystanos has been collecting antiques for years. His passion, however, is collecting old 78 RPM records, not
only for the market value, but for the music. An avid fan of swing, big-band and other genres long past, Mr. Curystanos
has quite a collection and has always wanted to share some of his rare titles with friends. Problem: Many of these titles
are one-of-a-kind and very valuable - not easily loaned or shipped without risk. Answer: Mr. Curystanos attended a
Smooth-On moldmaking and casting seminar (see page 17), and was soon making his own molds and castings at home.
The process was actually quite simple. That expanded into Ecos Castings
2.
1.
78s are nothing more than detailed wax and a 3,000 sq. ft. facility - the rest is
pressings and the mold rubber copied it beautiful music. Switching from tin-siliperfectly. But when we made the casting
cones to Smooth-Sil 945 platinum
and played it on my Victrola, the sound
silicone to make his molds, Curystanos
shocked everyone in the room.
has improved his mold yield from 40
-Christov
Curystanos,
Ecos
Castings
2- Smooth-Sil 945 is
1- Original 78 record
castings to over 300 per
mixed, vacuumed and
is secured in a box.
poured over model.
mold. And TASK 4
5.
plastic is ideal because
4.
it is unbreakable and my
records last far longer
3.
than the
original 78s - you can
3- Next day, the
drop them on the floor a
rubber mold is
4 - TASK 4 is mixed
5- The TASK 4 casting is
removed from the
dozen times and they
with SO Strong black
6. Perfectly . . . Everytime.
model, reflecting
removed from the mold and
each groove and even tint, poured into the
dont
break. Mr.
placed on a Victrola turnstile
the imprint from the
mold and allowed to
.
.
.
does
it
actually
play?
Curystanos began in 1999 and sales in 2002 were
label.
cure.
over $250,000. Curystanos declined
further notoriety in Smooth-Talkin stating, I dont need it - Im selling my records as fast as I can make them now.
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tm
Flame-Resistant Foam
Flame-Out 7 TM Rigid Foam is, as it sounds, a
7 lbs/ft. density rigid foam that is flame resistant.
The mix ratio is 1A:1B by weight, it has a pot life of
45 seconds and is tack-free in 10 minutes.
Like our Foam-iT! rigid foam products,
Flame Out 7 exhibits high tensile, shear strength,
and good impact resistance. Cured foam can be
machined, drilled, sanded, etc. and can be painted or
stained for wood grain or other decorative effects.
TM
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15
!
n
O
h
t
o
o
, Sm
HeyThere
are many factors that can contribute to mold rubber not curing including cold tem-
peratures, contaminants on a models surface, etc. But the most common reason: inadequate mixing of Parts A & B. People mixing rubber for the first time tend to under-mix the material before
applying. It is especially easy to under mix thick materials like silicone or brush-on rubber.
Mixing Success: A Function Of Time & Technique Time - Most mold rubbers give you plenty of time to mix and apply, so dont worry about not having
enough time. Your goal in mixing is to be thorough , not fast.
Technique: Dont Be Casual, Be Aggressive - This is where most first timers make the fatal mistake of using
a limp wrist, meaning that they are not aggressive enough in mixing the rubber. Use a stiff mixing paddle and employ
a firm wrist, making sure that you scrape the sides and bottom of your mixing container several tiems. Important material hides on the bottom and sides of your mixing container and failure to get this material into the mix will result in the
rubber not properly curing.
The Best You Can Do 2. Pour into new,
The
Double Mix-And-Pour
clean mixing container.
Technique - After mixing thoroughly for 3 minutes, empty the
contents of your mixing container and mix again for another
2 to 3 minutes before applying
over your model. This technique is your best bet for suc4.Pour slowly into
cessful mixing and protection
containment field.
your mold rubber investment.
3.Mix Again
1. Mix Thoroughly
16
Farthest distances traveled to attend: From Australia, China, India & Omsk (Russia).
Oldest attendee thus far: 82 years old. Youngest is 16 years old.
Attended most often: 3 years in a row and booked again for this year.
Most money ever paid for a $300 seminar slot; $550 sold at auction on E-Bay (?!).
Most felonious model: 12,000 year old Indian carving stolen from Atlanta museum.
(note: we didnt know the model was stolen until FBI showed up looking for it. Model
has since been recovered). Only seminar graduate to go to jail: same guy.
Oldest model: 150 million years; 6 Allosaurus claw from Denver Museum of Science.
Most historical model: death mask from President Ulysses S. Grant.
82 year old Bob Roberts
Most gaseous model: stalk of broccoli (yes, a stalk of broccoli).
Most mysterious model: we still dont know what it was - model was brought in by a displays his seminar
handiwork.
representative from the CIA, and he was not talking. Looked dangerous, though.
Most sexually explicit model: none -we dont allow those in our class, but people try (you have no idea!).
Most unique invention / reproduction: Rubber sneakers for horses.
Model most dead: rattlesake run over by car while driving to seminar from Oklahoma. Yes, we molded it.
Most romantic: couple that met at our seminar; married about 1 year later.
Most successful graduates: A tie. Some people leave our seminar inspired enough to start their own
mold making / casting businesses. 1 graduate now has her own candle making company; 1 graduate now
has an ornamental plastering/concrete business. Both had 2002 revenues in excess of $2 million.
17
The Pros: Mold Makers and Casters Who Will Do It For You
For those of you interested in having molds or castings made for you, we are proud to offer the following list of
professional mold makers and casters. If you would like to be added to this list, send an e-mail with your
business information to sdavis@smooth-on.com. This listing is updated regularly on our website: www.smooth-on.com.
Areas of expertise and rates may vary.
Other than supplying materials to these mold makers and casters, Smooth-On is not associated with and does not
warranty the work of any independent mold making and/or casting company.
Crow Atelier
207C S. Railroad Ave
Loveland, CO 80537
Contact: Tim Nimmo
Tel. 970-613-9237
Foundry/Sculpture, Molds for
Art Casting, On-Site
Monumental Molds
Daryl Davis
136 South Collin St.
Arlington, TX 76010
Tel. 817-548-3147
Molds for Artists - Silicone,
Urethane, Polysulfide, Molds
for Foundry Bronze.
(No casting.)
Phil Diers
1362 Hayes St.
San Francisco, CA. 94117
Tel. 415-567-3205
www.phildiers.com
lnskydrs@aol.com
Ornamental, Capitals, Bas Relief,
Architectural Detail
Felber Ornamental Plastering
1000 W. Washington St.
Norristown, PA 19404
Tel. 610-275-4713
Contact: James Kuryloski
www.felber.net
jk@felber.net
Architectural Restoration &
Ornaments, Mold Making, Casting
Peter Mastroianni
230 Austin Trail
Orangeville, PA 17859
Tel. 570 458 4936
Fax. 570 458 0449
www.pjmmold.com
peter@pjmmold.com
Mold Making, Prototyping,
Resin Casting
Walla Walla Foundry
405 Woodland Ave.
Walla Walla, WA 99362
Contact: Dave Anderson
Tel. 509-522-2114
Sculpture, Foundry
Mold Making Services
Jonathan Lewis
91 Hillcrest Rd.
Watchung, NJ 07060
Tel. 908-561-6189
Prototyping
18
Maslyn Studios
PO Box 723
Belle Mead, NJ. 08502
Contact: Tim Maslyn
Tel. 908-359-1618
Fax: 908-359-9426
www.maslynstudios.com
timmaslyn@maslynstudios.com
Sculpture, General Mold Making &
Casting Services, Memorials,
Awards
Garland Weeks
4101 N. Quaker Ave.
Lubbock, TX 79415
Tel. 806-749-6500
Sculptor & Moldmaker
(No Casting)
Battersby Ornamental
131 Balcones Hts.
San Antonio, TX 78201
Contact: Tom Battersby
Tel. 210-736-0459
www.battersbyornamental.com
tbattersby@satx.rr.com
Architectural Restoration,
New Work, Mold Making In-Shop
or On-Site, Casting, Sculpture &
Design
Nimba Creations
England
Tel. (44) 01271 343264
Fax. (44) 01271 343897
www.nimbacreations.com
nimbacreations@hotmail.com
Special Effects Company, All
Round Expertise in Molding &
Casting for Animatronics,
Prosthetics, Miniatures,
Set Work, Props for Movies, TV
L.E.I., Inc.
453 Cottage St.
Pawtucket, RI 02861
Contact: Lukas Ingendahl
Tel. 401-726-4550
Fax 401-724-6805
Sculpture, General Mold Making
& Casting Services
CohugeCo
4938 Gray Road
Cincinnati, OH 45232
Tel. 513-542-4341
Contact: Todd Myers
tmyers@cinci.rr.com
General Mold Making & Casting,
Toys, Electronics
Ceramic Imagineering
2093 Cedar Road
Nanaimo, B.C. V9X 1J6
Canada
Tel. 250-741-6539
Contact: Robin Thacker
rthacker@direct.ca
Ceramics, Plaster, Concrete,
FRP and Elastomers
Sculpture Services
37 Mowat Av. Unit # B3
Toronto, ON. M6K 3E9
Canada
Tel (416) 538-3934
Contact: Kevin Kilpatrick
sculpserv@eol.ca
Mold Making In-Shop or On-Site.
Casting, Fabrication and Props For
Artists, Designers and Architects
Ray Stankiewicz,
Consulting Engineer
866 Bohemia Parkway
Bohemia, NY 11716
Tel. 516-589-5254
Fax. 516-589-5261
New Product Design, Prototypes,
Model Making, Molding, Sculpting,
Casting, Architectural Models,
Patterns, Thermo Forming,
Injection Molding, Short Run
Production, Packaging Design
www.smooth-on.com
Sculpture Molds
50 Fuller Ave.
Toronto, Ontario M6R 2C3
Canada
Tel. 416-516-2023
Contact: Art Dilela
Molds of Sculptures, Model
Making,Architectural Models,
Sculpting, General Mold Making &
Casting Services
Landmark Casting
238 S. Belvidere St.
York, PA 17404
Tel. 717-812-8770
Fax 717-845-2935
Contact: Lonnie Barkby
landmarkcasting@suscom.net
General Mold Making & Casting,
Cold Cast Bronze & Resin Casting,
Fine Art Reproductions
Fun Fact!
Yes, Thats Martha - No, she is not on the list, but Martha
Stewart recently showed millions in the U.S. and Canada
how easy it is to make candle molds and wax castings
using OOMOO silicone rubber on her Living TV show.
tm
View & Print Technical Bulletins and Material Safety Data Sheets OnLine at www.smooth-on.com
19
TOLL-FREE: 800.762.0744
Presorted Standard
US Postage
Permit No. 180
Allentown, PA
www.smooth-on.com
Feather Lite
lightweight
plastic
. . . Page 14
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Since 1895
Often Imitated. . .
Never Duplicated.
The Best
Mechanical
Mixers Ever?
. . . Page 16
Softer
Flexib
le
Foam
On
Page 1
5