Making moulds is fundamental to our operation as a manufacturer of GRC products. And over the years we’ve got pretty good at it. In this blog we feature the first step in making a new fibreglass mould for a new seat shape in our POD range of street furniture. That first step is the plug.
Dave (who wishes to remain anonymous) is one of our three mould-makers, and he started on making the plug a week or so ago. The plug is the exact shape of the end product, and it is from the plug that he will make the fibreglass mould. We typically build the plug from timber materials or from CNC-cut high density foam.
Once the basic shape of the plug is made, the next step is to apply high-build coatings that are then hand-sanded and polished to a high gloss finish. This is the long and laborious step. The fibreglass mould surface will reflect the surface of the plug so it’s important the mould-maker (i.e. Dave) gets this step right.
Dave has photo-documented each step in the process starting with the timber materials, making the plug which in turn makes the mould for the newest member of our POD street furniture range, Bulb. Next week he will move on to step two – taking the fibreglass mould off of the plug.