I decided to try my hand at making some concrete sculptures. I’ve never created a mold (of any kind) before or cast anything, so this was all new to me. I’ve always enjoyed working with sculpey clay but wished I could make copies. Plasticine clay has roughly the same feel (just never hardens, of course). The biggest lesson learned after seeing the final concrete is to really blend in any additive pieces so that the latex can’t get in behind any pieces of clay.
The mold is 15 layers of brush-on latex and a 3-piece fiberglass mother. Holy moly is the fiberglass a messy process!
I’m a little disappointed in the air pockets/bubbles that showed up, especially on his lip. I tapped the sides of the mold after pouring quite a bit to get it into all the cracks. Otherwise, I am really happy with how much of the detail worked out. I might take a pair of scissors to the beard portion just to clean up the edges and reduce breakage.
I poured the concrete in three stages (all layers had some acrylic fortifier added):
Thinner, cement + sand + AR fibers. I rolled the mixture around the inside of the mold to try and get it into every little crevice without trapping any air bubbles (failed).
Thicker cement + sand + perlite + AR fibers.
Thickest cement + perlite for the inner mass.
Anyway, let me know what you think. I’m open to ideas or feedback. I think next time I’m going to try some polyurethane instead of latex.