This short video shows the process of making a faux bronze plaque and David Bowie life cast using a technique called cold-metal casting. First a silicone mold is made from a real wood plaque. Once you have the mold, bronze powder is dusted into the mold and a thin layer of fast curing polyurethane (TC-808) is applied behind the powder. Next, a batch of 6 pound rigid expanding polyurethane foam is cast behind the first layers of material to form a strong, lightweight part. Lastly, the part is demolded and the bronze powder surface is burnished to produce a realistic metal surface. The face casting is made in a similar fashion. Bronze powder, 3-4 layers of TC-808 is "slush cast" into a silicone mold. The face casting is then bonded to the plaque using BJB's Armor-Bond adhesive.

Brushed in Mold Bronze Powder Pigment by bitymoldsupply
Mold made with TC-5061 High Tear Strength Plat Silicone:
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TC-808 2-part polyurethane:
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TC-300 6# Rigid Expanding Foam:
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Brown Pigment for foam and TC-808:
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Armor-Bond Adhesive:
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