Sometimes when a project requires multiples of the same object, we may need to create a mould, which allows us to create copies. To do this, first we create a master, which is a version of what we want to replicate. This is coated with silicone and sometimes fibreglass which fills the negative spaces around the object. This is split up and supported to create the mould, then the master is removed to leave the positive space. Various materials can then be used inside of the mould to create the copies, this is called casting. We tend to use materials such as hard, rubbery or spongy plastics as well as fibreglass / GRP for larger or structural models.
We have used this production method for years in many projects, especially Event Prop Hire builds. We also provide a rotational moulding and casting service. This is where we use a machine to rotate the mould after we have put in the casting material. The main purpose of this is to reduce material cost as it allows you to cast a hollow replica with a thin plastic wall instead of a solid one.