A pretty young woman from Estonia named Kerly came to me in November 2009. She wanted something distinctive as a memento of her stay in Philadelphia. I sat her down in the studio and made a silicone mould of her lower face. I(n this first photo you can see me applying the first layer which becomes the face of the master mould.
Next step is to complete the first layer and add some gauze as the rubber sets up. Two more coats will follow in quick succession.
When the master mould is completed I remove it from Kerly and can now begin the casting process. Here is the completed mould and the first casting in hard urethane.
I made several more castings in urethane and finished them in a combination of aluminum powder and automotive clear urethane. This combination allows the casting and finish to chemically bond. The final finish is quite hard and durable and in this instance, looks like metal. Shine can be controlled by modifying the mixture of the clear coat.
Here is the model and the finished buckle in the studio. I am told that it has been very well received back in Estonia.