Making molds for concrete casting – home production for business and hobby

Making your own concrete casting molds can be a useful and satisfying project. Learning how to make molds opens up a world of possibilities, whether you’re a hobbyist hoping to create one-of-a-kind garden ornaments or a budding entrepreneur hoping to launch a small business. Molds that are long-lasting and precisely tailored to your requirements can be made with the correct materials and methods.

For those who are unfamiliar with the idea, molds are essentially containers that are used to shape concrete as it solidifies. These molds can have very basic shapes or very complex patterns that need to be made with care and precision. Gaining a basic understanding of mold-making can help you avoid common pitfalls and get the best results.

Selecting the right materials for your molds is essential. Wood, plastic, rubber, and even silicone are common choices. Every material has benefits and drawbacks that impact how easy it is to use, how long it lasts, and how detailed you can get. By looking into these possibilities, you can balance cost and functionality by choosing the ideal material for your particular project.

Concrete molds can be produced at home without needing to make a large equipment investment. Establishing a mold-making station in your garage or workshop only requires basic tools and materials that are easily found at hardware stores. This means that anyone who is willing to put in a little time and effort can participate in the activity.

The process of casting concrete is not too complicated once your molds are made. It is satisfying to mix the concrete to the proper consistency and pour it into your mold; this process turns raw materials into a finished product. You can make lovely and useful concrete objects, such as planters, stepping stones, decorative sculptures, and furniture, with a little perseverance and practice.

Purpose of cast concrete, its advantages and disadvantages

One type of building material that falls under the hydraulic engineering category is cast concrete. Its primary distinction from regular concrete is the addition of plasticizers, which give the mixtures exceptional elasticity and fluidity, and the use of fine-grained sand as a filler.

  • The main binder is cement. Various plasticizers and modifiers are used as additives, thanks to which the finished concrete has low shrinkage, easily spreads over the surface and does not delaminate.
  • Additives also allow moisture to be retained in the composition longer, due to which surface adjustments can be carried out over a longer period of time.
  • On many resources, you can see information that cast concrete does not need vibration compaction. Partly, this may be true, but not entirely. The fact is that air bubbles are intensively formed inside the mixture when it is mixed, therefore vibration when making figures of varying complexity, or rolling with a needle roller in the case of a self-leveling floor is simply necessary.
  • The final surface of cast concrete tolerates moisture much better (it penetrates its structure worse), due to which the material tolerates temperature changes perfectly.
  • Cast concrete is used not only for the production of finishing floor coverings. This material is very popular with designers of all stripes for creating decorative figures of various sizes and complexity. Here is a small photo gallery showing such creations.

Designer fantasy has no boundaries, as you can see. Because it is so versatile, concrete is used almost everywhere.

Making concrete casting molds at home can be a lucrative endeavor for enthusiasts as well as business owners. Using this method instead of purchasing store-bought molds lets you create personalized, one-of-a-kind designs while saving money. You can create sturdy molds for a variety of applications, from complex architectural details to garden ornaments, with basic supplies and tools. The possibilities and personal fulfillment that come with creating your own concrete molds are endless, whether your goal is to launch a small business or simply indulge in a creative hobby.

Molds for cast concrete figures

Concrete molds, also known as matrices, are special containers with the outlines of the necessary figure for production. The mold is filled with the necessary volume of plasticizer-containing solution, compacted, and allowed to dry for the necessary amount of time.

Counseling! Expanded clay, fine-grained crushed stone, marble chips, and other fillers can be added to the mixture if an unusual texture is required. Metal oxides are the primary pigments added when painting the figure in large quantities.

  • After the figure dries, it is carefully removed.
  • Most of the forms can be reused. Their service life is determined by the material from which they are made, the accuracy of the master who pours and removes, as well as the factory quality, that is, resistance to deformation, loads, etc.
  • Molds can be made of absolutely different materials. This includes plastic, silicone, polyurethane, wood, plywood, etc.
  • The choice of material depends, first of all, on the complexity of the figure being made.

There are two categories for all forms: hard and soft. The latter are composed of polymers, primarily silicone or liquid rubber, whereas the former are composed of chipboard, plywood, metal, wood, etc.

Complex figures, such as artificial stone or the same figures in the forms of people, animals, and other objects, are made with flexible forms. Since silicone is a long-lasting and highly durable material, it is mostly used as a basis. Its surface is so slick that pouring is possible without the need for extra lubricant to make removal easier.

Forms can also be classified as collapsible or non-collapsible. The second option is created in a single copy so that it can be destroyed afterwards when the figure is taken out. Given that this method obviously raises the cost of any production, what good is it?

  • The fact is that no matter how much you adjust the parts of the form to each other, there will always be some gap between them, into which concrete will definitely fall when pouring.
  • As a result, despite the fact that the product turns out to be solid, some semblance of seams remain along the contours of the joints, which, although slightly, spoil the appearance of the product.
  • The use of a non-separable form eliminates this problem, and the result is as if it came from the hands of a professional sculptor. So, in fact, non-separable forms are an attribute of handicrafts, which cost a lot of money.

How to make a form yourself

The process of creating forms for concrete casting can range from extremely simple to extremely complex. The geometry of the desired figure is what determines how complex a problem is.

  • Simple figures can be made without having a model. For example, to imitate artificial stone, you can cut out notches in the thickness of the foam. Such molds must be additionally strengthened so that they can withstand the weight of the poured concrete.
  • If the figure has a complex configuration, then the form for it must be cast, which means you cannot do without a model.
  • This is where skill is required, which we, amateurs, cannot have. The master will need the ability to sculpt from wax, plasticine, plaster or clay, as in the photo above.
  • So what can we make at home with our own hands, if talent and skills are not available? Yes, anything, provided that we have a ready -made product sample.

The following step-by-step guide will discuss how to achieve the desired form in an extremely easy manner. Consider a small concrete sink as an illustration.

  • We have at the disposal a finished plumbing product of a rounded shape.

That’s interesting to know! These days, these shells are installed for suitable pedestals in opulent homes throughout Europe, where they are highly popular.

  • It is necessary to start with the assembly of the box, which will serve as limiting sides for solidifying silicone.

  • Remove the actual dimensions of the product, then add 5-6 centimeters to them for the thickness of the walls.

  • Now, according to the obtained dimensions, we will need to make a small box in which the sink will fit freely, and the remaining space will be the place for silicone.
  • Suitable materials include wood, OSB panels and metal. In our case, the master took laminated chipboard, which he needed to cut into blanks.
  • It is very important that the edges of the parts to be sawn are perfectly smooth, so it is better to cut either on a machine or on a miter saw. If you only have an electric jigsaw, then make sure to get smooth, rigid guides that will allow you to cut smoothly.
  • The next step is cutting a hole in the working panel.

  • We take the workpiece, place it on a flat horizontal surface, and place our model on top.
  • Carefully and accurately trace the outline of the shell with a pencil.

  • Now we need to cut a hole along the resulting contour. We take a screwdriver and a wood drill, and drill a starting hole for a jigsaw blade. Drill so that the outer edge of the drill does not go beyond the intended radius.

  • It is quite difficult to be able to cut evenly with a jigsaw – the saw constantly tends to deviate from the line.

  • Exercise all your caution and do not rush anywhere.

  • Next, take the bottom of the box and carefully place our sink on top.

  • Put the previously made blank on top. After this, the sink is centered along the existing outline in the chipboard.

  • In order not to “knock down the settings”, draw straight lines on the edges of the panels with a marker, which we will subsequently combine. After this manipulation, the panel with the hole is put aside. Be careful not to move the sink.

  • Next, take some clay for modeling, cut it into strips, from which you then need to roll small "sausages", as shown in the photo above.

  • Then use the resulting blanks to cover the base of the sink. Be careful, do not leave gaps and do not accidentally move the model. Do not spare the clay – it should be squeezed upward when re-aligning the base parts.

  • The second panel with the hole is returned to its place and pressed down well. Do not forget that you need to accurately align the previously placed marks. A small gap will remain between the hole and the model at the top, which also needs to be sealed with clay
  • Take a small spatula and systematically go through the entire perimeter. The mass should not protrude, so remove everything from above flush and carefully clean the remains with a rag.

  • At the corners of our workpiece, you need to glue two or three closed nuts so that when pouring, recesses are formed in this place, which will serve for subsequent connections.
  • They are glued with hot glue so as not to delay the installation.

  • The next step is to attach the side walls. We install them using regular self-tapping screws. The parts are fastened along all the seams so that the seal is maximum.

  • From the inside, all the seams are coated with the same glue to close all possible cracks and make the structure airtight.

  • When the glue hardens, we will need to coat the inside of the mold with lubricant so that the silicone will easily come off later. For this, special compounds are used (preferably in the form of an aerosol), which you can buy in hardware stores.

  • Now you can start preparing the silicone mixture. We act strictly according to the instructions attached by the manufacturer. Pour the components into a bucket with high sides and mix everything thoroughly with a drill with a mixer attachment.

  • The prepared mixture is poured into our mold. However, you should not pour it to the brim, but so that the silicone does not reach the edges of the hole in the sink by a few centimeters.
  • After this, the liquid rubber is kept for about 16 hours at room temperature (about 23 degrees Celsius).
  • Now we need to make the second part of the mold.

  • To do this, again take our clay for modeling and carefully fill it with the rounding on the edges of the hole, that is, as if aligning it in the plane.

  • Next, from the same chipboard, we cut out a lid for our box. It should fit tightly in its place, and then be screwed on the sides with self-tapping screws. Now the entire form can be carefully turned over – the structure will have a solid weight, so be careful.

  • The screws that held the bottom cover are unscrewed, after which this element is carefully pried up and pulled out.

  • Next, remove the working panel with the hole along with the clay. Remove all remaining debris so as not to damage the mating part of the mold.
  • If the nuts that we glued in the corners are stuck in the silicone, then carefully pry them out with a screwdriver and also put them aside – they will no longer be needed.
  • Wipe the sink bowl with a clean dry cloth.

  • Knead the clay again and putty all the upper holes that were left from the screws with it, otherwise the silicone will leak into them when pouring.
  • Just as we did earlier, seal the mold with hot glue, then apply a layer of grease.

  • Again, we dilute our silicone and pour it directly into the bowl. Now fill the mold to the brim, then leave it to dry for the same 16 hours.

  • When the specified time has expired, you will need to disassemble the mold and remove the model from the inside. First, we unscrew all the screws and, using something flat and strong, remove the sides. Next, remove the top cover, after which you can take out the contents.

This causes a void to form where the removed sink was, into which we will pour concrete for casting.

As you can see, creating the mold is not a particularly difficult process, despite taking longer than expected. It’s important to realize that such enjoyment comes at a price, but that the product may be used repeatedly, potentially making the cost much more than once.

Topic Description
Materials Common materials for DIY molds include plywood, silicone, plastic, and metal. Choose based on the type of concrete and the desired finish.
Tools You might need tools like a saw, drill, and measuring tape. For silicone molds, you"ll need mixing tools and a mold box.
Design Tips Design molds with clear, simple shapes. Ensure they are easy to release the concrete from, and consider adding release agents to avoid sticking.
Assembly For plywood molds, assemble pieces using screws or nails. Ensure joints are sealed to prevent leaks. For silicone molds, mix and pour the silicone according to the instructions.
Finishing After casting, clean the molds and check for any imperfections. Sand down rough edges if needed to ensure a smooth finish on the concrete piece.
Safety Wear protective gear like gloves and masks when working with materials and tools. Follow all safety instructions for any products you use.

Whether you’re starting a small business or taking up a new hobby, making concrete casting molds at home can be a satisfying experience. Gaining the ability to create distinctive, personalized concrete objects that stand out comes from mastering this process. Depending on your level of experience and the scope of your projects, the methods you select can range from easy do-it-yourself projects to more complex strategies.

Playing around with various mold materials and shapes can be an enjoyable way for hobbyists to express their creativity. You may discover that creating personalized coasters, ornamental items, or tiny planters can be gratifying and fun. Every mold you make is a chance for you to hone your craft and acquire new knowledge, transforming commonplace items into artistic creations.

However, accuracy and consistency become essential if you plan to make this into a business. Making the time to learn about the characteristics of mold materials will enable you to create long-lasting, high-quality products. By practicing, you can carve out a niche for yourself in the concrete creation market and sell one-of-a-kind products that suit a range of preferences and requirements.

In the world of concrete, knowing how to make molds is a useful skill, whether for leisure or business expansion. Accept the learning curve and take pleasure in the process of realizing your tangible concepts. Have fun with the casting!

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