On this page we will attempt to provide a step by step  guide to illustrate how an idea, to be made of Concrete, is turned into a usable, saleable product.

1. A sketch or drawing is made incorporating the idea.
2. A full size model is created from the Sketch or drawing, using a suitable material such a modeling clay, wood, plaster, etc.
3. If the full size model can withstand the high tempetures of Thermoforming (300-400º F), an ABS plastic mold can be made from the model and a protype product can be made from the ABS mold.
4. If the model cannot withstand the heat of thermoforming than a reverse cast of casting plaster can be made from the model.
   
5. From the reverse cast, a plaster model can be cast from the reverse cast. Then the ABS mold can be made from the plaster model.

At any time during this process, attention must be paid to be sure there are no under cuts anywhere on the final model and there is sufficient unrestrictive draft on all verticle surfaces ( generally a 2-3% angle is sufficient for easy release of the mold from the model and sequently the concrete product from the mold ).

Throughout the molding and concrete casting process a quality mold release spray or brush-on product must be used each time a mold or concrete product is made.

Reinforcing:

Whether internal reinforcing is required or necessary generally is determined by the Craftsmen. On small ( under 1/2 cubic foot of concrete ) products it is not necessary. However if there are thin extensions that could be subjected to stress, then some type of reinforcement would be advisable. Either 1/4" reinforcing rod or larger could be use. keep in mind there should be at least 3/4" concrete coverage around rebar to prevent spalling in the future.

This page currently under Construction, give us a few days and Check Back, for updated information.

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