Maintaining Detail With Silicone Rubber Moulding
Here at 3D Pattern and Mould Makers, we have many years of experience creating silicone rubber moulds for different projects. These flexible and versatile moulds offer something that other materials don’t, allowing us to meet the needs of even the most specific jobs. One of the most popular applications is in the construction of detailed stone casts and, in this guide, we’ll take a look at why rubber designs are the best solutions on the market.
Why Silicone Rubber?
Choosing the right manufacturing technique ensures a high-quality result. A key consideration here is the material you choose. In modern moulding, there are four main materials used – plastic, rubber, timber and steel.
Plastic Moulds – For larger-scale, commercial projects where bulk quantities are needed in various designs, ABS plastic is the favoured material. It is strong and lightweight with good durability and can be manufactured quickly to various specifications.
Rubber Moulds – If you’re looking for more flexibility with the design, a bespoke end project and something that reduces the risk of damage on the final project, opt for rubber. The moldability of this material means it can be used in a wide variety of applications, and because rubber can be cast in different shore hardnesses, it can be easily made bespoke for each client.
Timber moulds – Alongside rubber, timber moulds are commonly used when working with concrete. They are ideal for big construction projects, offering durability but less able to provide intricate detail.
Steel moulds – On the large and industrial side of the scale are steel moulds. These are ideal if you want to produce items on numerous occasions and require a mould to last for many years.
Benefits Of Silicone Rubber Moulds
Here at 3D Pattern and Mould Makers, we manufacture both polyurethane rubber moulds and timber moulds for various applications. While both have their unique benefits, it is the rubber alternatives that are best favoured for high-detail projects. And, within this, you’ll generally find two options – polyurethane rubber or silicone rubber. Each one has its benefits and suits different applications – PU rubber is ideal for large form liner manufacturers while silicone rubber is far more suited to highly intricate cast stone and concrete projects. Let’s take a look at the benefits of each material below:
Polyurethane Rubber Moulds
Pros:
Has good wear resistance and can be used hundreds of times to create identical products
Strong tear abrasion
Can be used to create complex designs
Cheaper to manufacturer for bulk projects
Denser, therefore less is required to make the same sized mould as silicone
Cons:
Higher shore rating makes it unsuitable for certain projects (10 shore A > 95 shore A)
Requires the use of a releasing agent
Silicone Rubber Moulds
Pros:
Wide range of shore options (6 shore A > 80 shore A)
Good release properties, eliminating the need for a releasing agent
An efficient demoulding process makes it ideal for complex projects
Allows for high levels of accuracy in any design – especially when recreating an original pattern or detail
Cons:
More expensive and generally not used for mass-production
Lower tear and abrasion resistance (dependent on the shore)
As you can see, each type has its own benefits and drawbacks. Since both can also be used in the casting of concrete or stone, recognising the need for detail is key when choosing the right option. We work with many clients looking to recreate traditional, intricate carvings during restoration projects or artists with exacting designs in mind. Silicone rubber offers the flexibility and versatility required in such projects while polyurethane works best for industrial projects where hundreds/thousands of an end project is needed in quick succession.
Silicone rubber mould applications
As we’ve mentioned above, one of the key uses of silicone rubber moulding is in the restoration of buildings. During such projects, the goal is to maintain the story, history and beauty alongside the detail. Sourcing the right traditional material is key but, for us, the importance comes in having the right tools to work this material into an exceptional final project.
Because rubber is poured, it can match any complex geometry that is required. The patterns are generally machined using CNC machinery, which means any variety of designs to be easily achieved, from fluted columns through to such as the Elgin marbles replicate we created for the London 2021 Olympic Athletes Village Complex. Over the years, we have used rubber moulds on a wide range of different projects, including:
Precast bench end manufactured from a seamless rubber jacket
Corinthian capital moulds
Seamless flag bases for London 2012
Intricate formliners for use in construction projects
Fluted roof soffits for Broadgate Ticket Hall
Dentilled cornices
Alongside these specific projects, rubber moulds can be used for everything from concrete countertops for kitchens to larger statues and even items of furniture. The versatility is one reason why they remain highly popular to this day.
Are They Right For Your Project?
Both silicone moulds and polyurethane moulds continue to be used widely, on various projects and to meet exacting needs. For those working with concrete and seeking bespoke designs, they are an ideal option. Considering the best option between the two requires the support of a professional team who can best understand the needs of your specific project. From how the end product needs to perform, how many items are required and the budget, 3D Pattern and Mould Makers are here to ensure you find the right solution.
With a dedication to providing quality products to all of our customers and prioritising innovation for the needs of your project, we’re here to help. If you have any further questions about silicone or polyurethane rubber moulds or would like to speak to a member of the team, please do get in contact with us here today.