Methodology

1. 

   Step 1: Creating the Design

   Every project starts with some sketches and brainstorming until a solid idea can be conceptualized. From there, the design is 3D-modeled in Rhino3D and Grasshopper where it can be visualized and rendered to see how it would look realistically. Many iterations are then made to find the best design possible for fabrication.

3. 

   Step 2: Creating the Mold Designs

   Once the design has been completed, an inner and outter mold is then made using the Dendro plugin for Grasshopper. This plugin allows us to create molds that ensure silicone will only be cast where it is needed, greatly reducing the cost of the project. This method ensures we use the least amount of recources necessary to achieve the greatest amount of details possible.

5. 

   Step 3: Creating the Silicone Mold

   Once the molds have been printed, they are placed together and all gaps are sealed to prevent any leakage. Silicone is then painted on to the inner mold, allowing it to seep into every crevice, and then poured into the outer mold. Both molds are then placed together and the silicone is left to cure for six hours. Once complete, the silicone mold is examined and any imperfection is then corrected.

7. 

   Step 4: Casting the Concrete

   Every project has their own set of conditions that need to be assessed before the concrete mix can be made to ensure the most optimal mix design. The concrete mix is different for sculptures that rest on a flat tabletop surface to pieces that are hung up on a wall. Once a mix design has been made, it's casted in the silicone mold and a custom 3D-printed support structure is placed inside the concrete if needed.

9. 

   Step 5: Letting the Concrete Cure

   The curing process depends on the size of the project. For smaller scale sculptures, the concrete is left to cure in a tub of water completely submerged for two weeks. For larger scale sculptures and wall art pieces, the concrete is left to cure in the mold where it is misted at a consistent rate throughout the process to avoid it from drying up. Once cured, the concrete is polished and waxed as needed, and then finally it is ready to be enjoyed!