Frequently Asked Questions - Moulds
Please find following our list of frequently asked questions (FAQ's)
regarding our moulds and mould making techniques.
Q: How do we make our moulds?
We often get asked this question as neither Joan, Stef,
Adam, or myself are what you could call a sculpturing genius. It
took us over 12 months working hard to modify the industrial production
methods that we use to make hobby and professional style vacuum
The usual production method for making this type of mould, is
to start off by sculpting your original in potters clay or one
of the newer air hardening or oven hardening clays. Then making
a plaster or RTV rubber mould of the finished sculpture. A casting
of this mould is then made in either aluminium resin or Drystone
or Hydrostone gypsum and mounted up for future vacuum forming.
This is a skilled process that can take weeks to finish.
By taking small steps and modifying as you go you can achieve
results that are not dissimilar to the work of a professional
sculptor. Car bodies are set up for manufacturing by producing
models and modifying as you go till a final design is approved
We sculpt a working model, make a vacuum formed mould, cast an
intermediate model, refine it, alter it slightly, make another
mould refine it again until we are satisfied with the result and
then and only then do we make our production model for future
We also work from sketches, drawings and photographs of proposed
moulds using a modified industrial CAD/CAM program. It cost some
tens of thousands of dollars and we live in hopes that one day
it may begin to pay for itself. We worked on it for some 12 months
before opening for business to adjust it to our proposed method
of production and it is only now beginning to show that our time
was not wasted.
Basically we take a 2D flat sketch, clean it up, modify it and
give it a 3D appearance with the tools built in to the program.
Then we rastorise or vectorise it, calculate a machining path
and then send it to our CNC for final processing before vacuum
forming-and if this all sounds a bit over the top, it is!
If you look closely at our latest moulds you will see a much
greater degree of detail than in the usual imported moulds. We
are continually raising our production standards and we hope it
is beginning to show. One of our latest moulds took 48 hours machining
time for a job that normally would take 4 to 6 hours. And this
for a hobby mould! Job satisfaction is what it is, at least that
is what you call it when you can't justify it cost wise.
Q: Are you ever out of stock of one
of your products?
A: Except for a limited showroom display stock, we manufacture
all of our moulds after receipt of your order so we should never
be in a position not to be able to supply you.
The Supercast latex range however is imported from England and
many of the mould making materials are imported and could be out
of stock for limited periods. We remove any item O/S from our
website on a daily basis. We will contact you by email to see
if you would like the item placed on backorder.
Q: Do you have a showroom?
We occupy industrial factory premises at 22A Hearne Street
Mortdale and have a small area set aside for display and direct
sale from 8:30am - 4:30pmpm Monday to Friday. You are welcome to
visit us at any time.
Q: Are the moulds reusable?
Treated with care our vacuum formed moulds and latex moulds
will last for years and produce many castings. If latex is exposed
to continuous heat and sunlight, the mould may only last for 12
months before starting to deteriorate.
Q: Are your moulds suitable for fetes
or plaster parties?
A very large number of our hobby moulds are used just
for this purpose. Many fetes use our moulds and add a few new ones
each year to add variety. Get a volunteer, usually a retired person
to pour the moulds and the rest is pure profit. A wonderful fund
raiser and immensely popular with the children.
Q: What are latex moulds and what are
they used for?
Latex rubber moulds produce a 3D object rather than a
plaque or flat backed object such as is produced using vacuum formed
They are much more difficult and labour intensive to produce and
consequently are much more expensive than plastic moulds. The plaster
is poured into the latex mould and when hard the mould is removed
by pulling off much the same way you would remove a sock from your
We have available a kit, complete with everything you need to make
latex moulds available on our eBay
Q: What and where can I sell my finished
plaster and concrete ornaments?
This proved to be too big and important a subject to just
answer briefly - so we compiled a book for concrete that is listed
on our website and are preparing a similar publication for plaster
- which will be listed when completed.
The idea was "We tell all" all the trade secrets from
making the product and decorating and then making money from all
your good work.
Those who take the time and labour to become professionals in this
field are making good money from their efforts. It's one of the
fields where "Big Business" cannot compete - the local
producer has all the advantage. No freight costs, low material costs
and so very high profit margins.
We intend to provide all the information we can to help the "start
up" businesses in this field. Watch our newsletter and websites.
For our free newsletter email us at firstname.lastname@example.org
and leave your name and email address or complete the easy signup
Q: How many pieces can I pour from my
With vacuum formed moulds this greatly depends on the
flexibility required and the thickness and type of plastic used.
The thicker the plastic the longer the life. For our hobby moulds
we use 0.5 to 1.00mm plastic while for our professional concrete
moulds we use thicker ABS. Even our thinnest plastic hobby moulds
will last for years and with care produce many dozens of casts.
Our production moulds will yield 100's of castings. We have yet
to wear one out.
Q: What type of plaster do you use and
where do you get it?
There are many different types of plaster made from the
coarse builder's Plaster of Paris to pottery and dental plasters.
All have their uses. The plaster we recommend and use is called
casting plaster and is manufactured by Boral and C.S.R
This plaster has an ingredient added that hardens the surface and
gives a beautiful finish. The risk of chipping is reduced and the
surface is ideal for decorating with hobby acrylic paints.
It is usually available from local plasterboard suppliers and if
they don't stock it, they can order it in for you. We can supply
this idea by courier - but freight costs are such, local supply
is the preferred. Contact us for information on how to mix and pour
Q: What do you use to decorate plaster
and decorate concrete ornaments?
For plaster we recommend sealing with an acrylic sealer
either spray or brushed and using hobby acrylic paints to decorate
- followed by another spray of the acrylic sealer. Concrete is usually
antiqued by brushing the finished ornament with a metallic oxide
mixed with water and then wiping off the colour on all the raised
portions with cloth to leave the colour in the recesses.
Further information is available on our new website www.moulds4concrete.com.au
Ordering and Payment System
Q: What types of payment do you accept?
Credit cards including Master card and Visa - Pay Pal
- Personal Cheque - Money Orders - or direct debit into our bank
account which is Westpac Rockdale NSW BSB - 032 057 Account Number
If you are uncomfortable with having your credit card details online;
(our site is secure with 128 bit encryption) you may phone us during
business hours 8:30am - 4:30pm Monday to Friday on 02/9533 9555
or internationally 0061 2 9533 9555, making sure you include your
name and the delivery address with quantity and stock number for
the item ordered.
Payment details should include your full card number, expiry date
and name on card.
You can also fax your order to 02 9533 9955
If ordering by email Do Not leave your card details as it's not
Q: How long does it take to receive
We endeavour to ship all orders within 24 hours of receipt
of your payment. It takes 3-4 days for Australian shipment to arrive.
5-10 days for the UK and USA. Most other countries within 14 days.
Q: Do you offer quantity pricing?
You are buying direct from the manufacturer. There is
no wholesaler involved. Our mould prices are trade prices less the
following overriding discounts for quantity buyers.
10-19 moulds Less and additional 5% discount
20-29 - 10% discount
30-39 - 12% discount
40-49 - 15% discount
50 & over - 20% discount
Q: Do you ship your goods Worldwide?
We endeavour to give you as close a freight estimate as
possible with each item or range of items for standard post. Some
Resins in the fiberglass mould making section cannot be sent by
post and require courier delivery.
Q: Do you ship worldwide?
Yes, we post to all countries worldwide. Our hobby moulds
are light and cost little to post. Please email for postage rates.