| 1. The inner, rubber, "skin" | |
|---|---|
 | Each mould has a flexible rubberized interior to capture every tiny detail of the original sculpture. This rubberized interior is made by pouring the rubberized material over the original wax maquette (covered with release compound to prevent the rubber from sticking to it) and enclosed within a specially constructed form to permit only a narrow thickness of rubber to form. Once dry, the outer form is removed and the rubber "skin" is peeled off the original wax maquette. This rubber skin is then used as the interior of the final mould. As to the outer form, it is saved for the final mould construction. The rubber skin (forming the interior of the mould) can be seen in the image at the left. Notice that it is flexible to the touch (Pierre's thumb is bending it open and to the left) -- this very flexibility is what permits the rubber to pick up every original sculptural detail. The rubberized interior of the mould is encased in the protective stiff outer form (already referred to above) to prevent the rubber interior of the mould from bulging with the weight of the casting material. And finally the stiff outer form is encased within a wooden box -- split down the middle at a "parting line". |
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| 2. The outer, stiffened skin and the wooden container | |
 | Here the final mould can be seen -- with the rubber skin nestled within the rigid outer form, itself encased in the wooden box. Of course, the outside of the rubber skin follows the general shape of the lion but doesn't have all the minute details that are captured in the rubber skin's interior. After the two halves of the box are clamped together the mould will be stood on its head and the casting material poured in an opening left at the base of the feet. This upside-down pouring ensures that any bubbles (minimized, in any case, by a special vibrator machine Pierre built) will form at the base of the feet, where they are concealed, and not at the top of the lion. |
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| 3. Casting | |
 | Here a casting (of a table top) has just been poured. Here the casting material is still wet and just starting the drying process. |
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| 4. The Completed Cast | |
 | A newly removed lion-claw-foot casting, ready for any type of finishing desired. |
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