Elements and Performance Criteria
- Develop mould design
- Establish original product concept or design from drawings, originals or consultation with the customer
- Sketch out product prototype design and establish product sizes making appropriate allowance for material shrinkage
- Identify areas where undercuts, cutbacks or other special features are required
- Determine parting line
- Determine material from which mould is to be made
- Select mould material and prepare for mould production
- Set up material for mould making, ensuring that the mould can be handled or moved without damage
- Establish datum point and mark out design dimensions using geometric and lineal calculations
- Determine correct cavity depths and contours
- Ensure there is adequate ventilation and light to facilitate an appropriate work environment
- Produce working mould
- Fit appropriate protective equipment to prevent inhalation or irritation of by-products of the mould making process
- Use appropriate tools to carve out mould cavity and detail
- Accurately follow the design detail to produce a mould cavity to specification
- Avoid undercuts which will prevent removal of the plaster product from the mould
- Ensure appropriate degrees of taper are provided to facilitate product removal
- Carve reliefs according to design and remove debris as the work proceeds
- Complete mould
- Produce product prototype
- Apply slipping agent to mould surface
- Prepare and insert anchors or ties
- Prepare plaster mixture and appropriate amount of glass fibre
- Cast plaster mix and fibre into mould cavity, strike off and allow to set
- Remove prototype from mould or mould from prototype
- Check prototype for dimensional and detail accuracy
- Compare prototype and mould to identify any faults or mould inaccuracies
- Adjust or dress mould to remove imperfections and clean mould surface
- Cast second prototype and recheck product and mould
- Clean up mould and mark in accordance with organisation identification practice
- Control hazards
- Respond to problems