Abstract:
A method of forming a three-dimensional sculpture comprises the steps of providing a mold having a lining and a casting cavity, applying a powder to the mold lining, pouring a casting material into the casting cavity and curing the casting material to form a casting object, said powder being transferred to said casting object during curing of said casting material, and removing said casting object from said casting cavity to form a powder-laden three-dimensional sculpture.

Description:
FIELD OF THE INVENTION  
         [0001]    The present invention relates generally to a method of forming a three-dimensional sculpture, and more particularly to a method of applying a fine powder to a mold surface and then casting an object from such mold to form a three-dimensional sculpture having an aesthetic appearance dictated by the adherence of the fine powder to the mold casting.  
         BACKGROUND OF THE INVENTION  
         [0002]    Prior art methods of forming three-dimensional sculptures with acrylic and clear plastic castings are known to involve the spray-painting of a liquid-base medium onto a clear or plastic three-dimensional object and then pouring a casting material over such painted object and into a mold to form a paint-coated three-dimensional casting sculpture. However, the use of paint with certain kinds of acrylic or clear plastic objects can be very limiting, particularly since such a liquid-based medium is washable when embedded and can produce separation in the process of casting.  
           [0003]    Recognizing the limitations of the prior art, the present inventor has devised a method of creating a clear three-dimensional sculpture by using molds with linings that are particularly adapted to receive and retain a fine powder material. During casting, the fine powder material is transferred to the object defined by a casting cavity and this results in the transformation of the casted object into an aesthetic sculpture. The resultant casted object is clear with the exception of the transferred powder that covers its outer surface or surfaces and provides an aesthetic contour to the casted object.  
         SUMMARY OF THE INVENTION  
         [0004]    A method of forming a three-dimensional sculpture comprises the steps of providing a mold having a lining and a casting cavity, applying a powder to the mold lining, pouring a casting material into the casting cavity and curing the casting material to form a casting object, said powder being transferred to said casting object during curing of said casting material, and removing said casting object from said casting cavity to form a powder-laden three-dimensional sculpture. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0005]    [0005]FIG. 1 is a front view of a three-dimensional model used to illustrate one embodiment of the method of the present invention.  
         [0006]    [0006]FIG. 2 is a rear view of the model of FIG. 1.  
         [0007]    [0007]FIG. 3 is a side view of the model of FIG. 1.  
         [0008]    [0008]FIG. 4 illustrates the creation of a mold using the model of FIGS. 1-3.  
         [0009]    [0009]FIG. 5 is a top view of one mold half used in the method of the invention.  
         [0010]    [0010]FIG. 6 is a top view of the other mold half used in the method of the invention.  
         [0011]    [0011]FIG. 7 is a cross-sectional view of the mold half of FIG. 5.  
         [0012]    [0012]FIG. 8 is a cross-sectional view of the mold half of FIG. 6.  
         [0013]    [0013]FIG. 9 illustrates one method of applying powder to a mold surface.  
         [0014]    [0014]FIG. 10 illustrates the casting of a material inside a mold formed from mold halves illustrated in FIGS. 5-8.  
         [0015]    [0015]FIG. 11 illustrates a casting object formed in accordance with the method of the invention.  
         [0016]    [0016]FIG. 12 illustrates the casting object of FIG. 111 embedded in another mold in accordance with a method of the invention.  
         [0017]    [0017]FIG. 13 illustrates a sculpture formed in accordance with the method of the invention.  
         [0018]    [0018]FIG. 14 illustrates an alternative embodiment of a casting object formed in accordance with the method of the invention.  
         [0019]    [0019]FIG. 15 illustrates an alternative embodiment of a pair of molds situated in preparation for casting in accordance with the method of the invention.  
         [0020]    [0020]FIG. 16 illustrates the joinder of the molds of FIG. 15.  
         [0021]    [0021]FIGS. 17-18 illustrate a casting object formed by using the molds of FIGS. 15-16.  
         [0022]    [0022]FIG. 19 is a top view of an alternative embodiment of a casting created in accordance with the method of the invention.  
         [0023]    [0023]FIG. 20 is a side view of an alternative embodiment of a casting created in accordance with the method of the invention. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0024]    The following detailed description is of the best mode or modes of the invention presently contemplated. Such description is not intended to be understood in a limiting sense, but to be an example of the invention presented solely for illustration thereof, and by reference to which in connection with the following description and the accompanying drawings one skilled in the art may be advised of the advantages and construction of the invention. In the various views of the drawings, like reference characters designate like or similar parts.  
         [0025]    [0025]FIG. 1 is a front view, FIG. 2 is a rear view and FIG. 3 is a side view of a three-dimensional spherical model  50  used for purposes of illustrating one embodiment of the method of the present invention. A square protrusion  60  extends from the front of the model  50 , while a round protrusion  70  extends from the rear of the model  50 , both protrusions  60 ,  70  being visible from the side view of FIG. 3 and are present in this example to distinguish between the front and rear sides of the model  50 . For purposes of explanation, the model  50  is formed from a solid, opaque material such as clay, metal or rubber, and is being illustrated as a very simple shape. More complicated shapes are clearly contemplated. As will be illustrated below, the desired outcome is a clear, three-dimensional sculpture with a powdered outer contour that is reflective of the outer surface contour of the three-dimensional model  50 .  
         [0026]    [0026]FIG. 4 illustrates the simplified creation of a silicone mold  100  of the three-dimensional model  50 . The model  50  may be supported in a plaster mold with silicone material cast around the model, or other methods of creating the mold  100  may be used. The mold  100  is then separated into first and second halves  110 ,  120  illustrated in FIGS.  5 - 8 . FIGS. 5 and 7 illustrate an impression  115  of the front side of the model  50  (FIG. 1) and an impression  120  of the square protrusion  60 . FIGS. 6 and 8 illustrate an impression  130  of the rear side of the model  50  (FIG. 2) and an impression  135  of the square protrusion  70 .  
         [0027]    Such impressions  115 ,  120 ,  130 ,  135  form the mold surfaces  125  (FIG. 7),  140  (FIG. 8) on which powder  150  (FIG. 9) is applied. First, however, the mold surfaces  125 ,  140  are cleaned with a high-powered jet of air and brushed on with a very soft brush to create an electrostatic charge on the mold surfaces. Other methods of inducing an electrostatic charge are also contemplated. Such charge assists the application and retention of very fine powder  150 , such as particles of translucent mica or any other fine powder, such as mineral powder, metal powder, dry colors and the like. Other types of particulate material are contemplated.  
         [0028]    Once the mold surfaces  125 ,  140  are cleaned, powder  150  is applied preferably by using a brush  160  as shown in FIG. 9. The bristles  165  of the brush  160  may be applied directly (swiped) to one or both of the mold surfaces  125 ,  140 , or the brush  160  may be vibrated (by hand or mechanically) above the mold surfaces  125 ,  140  to dust the powder onto the mold surfaces. Other methods of applying powder such as shaking the brush (raining) or controlled tapping of the brush above the mold surfaces, or a combination of tapping, brushing, dusting, dry spraying (with a dry spray gun for example) and raining may be used at various locations along the mold surfaces to create the desired end result.  
         [0029]    The powder will be attracted to the mold surfaces  125 ,  140  and stick thereon by virtue of the electrostatic charge imparted thereto as discussed above. Powder may be applied to one or both of the mold surfaces  125 ,  140 , and such application may be of uniform or varying intensity. For example, if applying powder to both mold surfaces  125 ,  140 , it may be preferable to apply a higher intensity of powder or use a darker color powder on one mold surface relative to the other mold surface so that such higher-intensity surface will be more pronounced and visible when the three-dimensional sculpture is formed.  
         [0030]    Once the powder has been applied to the mold surfaces, excess powder may be removed with low-pressure air and afterwards, the mold surfaces are brought together and enclosed (FIG. 10) in a casting mold having halves  170 ,  180 . Because the mold surfaces are charged, a low pressure jet of air will not disturb the powder that has been applied to the mold surfaces. An opening  190  is provided through the mold halves  170 ,  180  and  110 ,  120  to provide access to a casting cavity  200  defined between the powder-laden mold surfaces  125 ,  140 . A plastic material  210  such as clear polyester, acrylic, epoxy or the like is then introduced into the casting cavity  200  through the opening  190  and then allowed to cure until the casting material  210  hardens. Such curing may be expedited by varying the temperature and/or pressure of the mold environment. The material  210  is selected so that it cures transparent or translucent, even though the material  210  may not be clear when it initially enters the casting cavity  200  as is the case with some plastics.  
         [0031]    After the casting material  210  is cured, the casting object  220  (FIG. 11) is removed from the mold  110 ,  120  as shown in FIG. 11 to form a three-dimensional sculpture. The powder  150  that originally lined the mold surfaces  125 ,  140  (FIG. 10) has been transferred from the mold surfaces  125 ,  140  to the casting object  220 , such that the outer surface  225  of the casting object  220  is covered with powder  150 , while the interior  230  of the casting object  220 , or the casting object as a whole, is clear (preferably transparent or translucent depending on the nature of the casting material  210 ). If the silicone mold surfaces are too dry during the electrostatic charging process described above, a release agent may be sprayed onto the mold surfaces to assist in the transfer of the powder to the casting object and the later separation of the casting object  220  from the mold surfaces  125 ,  140 . If, however, the powder is too densely applied such that the powder is not evenly transferred to the casting object, any residual powder may be sandblasted or washed off the mold surfaces in preparation for the casting of another object.  
         [0032]    Thus, for example, the powder-coated surface  235  (FIG. 11) around the round protrusion (see FIG. 2) may be visible through the interior  230  of the casting object  220  by looking through the powder-coated surface  240  around the square protrusion. This is particularly the case if, for example, a fine or light-colored layer of powder was applied to the mold surface  125  and a heavier or dark-colored layer of powder was applied to the mold surface  140 . Similarly, if, for example, a red-colored powder was applied only to the mold surface  125  on the square impression (see FIGS. 5, 7), and a gold-colored powder was applied to the remaining mold surface  125 , and a light-silver powder was applied to the entirety of the mold surface  140 , the casting object  220  created therefrom would have an aesthetic quality whereby the square portion  240  is red and visible by looking through the round portion  235 .  
         [0033]    The powder-laden three-dimensional sculpture formed by the casting object  220  may be further aesthetically improved by suspending or otherwise supporting the casting object  220  within another mold  250  (FIG. 12) and then introducing the same casting material  210  (FIG. 10) around the casting object  220 . Introducing the same casting material  210  around the casting object  220  does not disturb the powder that has already adhered thereto because such powder has become chemically bonded to the casting object and will not easily release therefrom. Once the same casting material  210  cures in accordance with the discussion above, such cured material  260  (FIG. 13) and the embedded casting object  220  are removed from the mold  250  to form a three-dimensional sculpture  270  (FIG. 13). Because the cured material  260  is formed from the same material that was used to form the casting object  220 , and because the cured material  260  is clear upon hardening, the casting object  220  appears to float or be suspended within the cured material  260 . The cured material  260  can be finished by cutting, polishing or the like to provide an aesthetically pleasing sculpture  270 .  
         [0034]    Various aesthetic modifications can be imparted during the creation process that can drastically change the resultant casting object. For example, FIG. 14 illustrates a casting object  280  having a different appearance on each half of the object. On the left side  282 , the powder covering exhibits a cracking appearance, which is the result of an increased density of metal or mineral powder applied to its corresponding mold surface. If casting object  280  is formed from molds  110 ,  120  (FIGS. 5-10), then the cracking effect  282  would be created by applying a heavy layer of powder on mold surface  125 . The cracking effect can be controlled by modifying the amount and type of powder applied to the mold surface. The cracking (aging) effect will happen only when the object is embedded into the clear material (see FIGS. 12-13) due to the 5-7% shrinkage of the material in the process of curing. To eliminate the shrinkage effect, the embedded piece should be in an uncured state. On the right side  284  of the casting object  280  there is provided a plurality of shaped sections  286 ,  288 ,  290 ,  292  that are generated by applying powder only to discrete portions of the mold surface  140 , with the remainder of the mold surface being free of powder. By applying powder only to discrete portions of the mold surface, the resultant powder sections on the casting object appears to be floating in space. This is particularly evident if the casting object is then embedded in another casting as shown in FIGS. 12-13.  
         [0035]    [0035]FIGS. 1-14 illustrate a simplified explanation of the method of the present invention. Such method can be applied to create various artistic works. For example, while FIGS. 1-14 illustrate the creation of a three-dimensional sculpture  270  from a single three-dimensional model  50 , a three-dimensional artistic sculpture can be created by using a combination of two or more separate pre-existing objects or models.  
         [0036]    For example, to produce a unique three-dimensional object or sculpture  400  (FIG. 18), two or more independent, pre-existing sculptures or objects can be used to create molds that are then combined to form the sculpture  400 . FIG. 15 illustrates a first silicone mold  300  supported by a first support mold half  310  and having a mold surface  320  that is representative of an artistic feature from a first object or sculpture (not shown). A second silicone mold  330  supported by a second support mold half  340  has a mold surface  350  that is representative of an artistic feature from a second object or sculpture (not shown). The mold halves  310 ,  340  are then brought together (FIG. 16) and a casting material is introduced into the casting cavity  360 .  
         [0037]    [0037]FIG. 17 illustrates the casting object  370  formed with first and second surface contours  372 ,  374  that are each representative of independent objects. Thus, if one object is a dog face and the other object is a cat face, the first surface contour  372  might represent the image of a dog, while the second surface contour might represent the image of a cat. Continuing with such example, the resultant sculpture  400  (FIG. 18) would then have the positive image of a dog on one side  376 , and the negative image of a cat on the other side  378 . Such sculpture  400  could then be used to create a powder-laden three-dimensional sculpture  270  as shown in FIG. 13 and in accordance with the method illustrated in connection with FIGS. 1-14, wherein a positive image of a dog would be viewable by looking at one side of the sculpture  270  and a negative image of a cat would be viewable by looking at the other side of the sculpture  270 , and a spaced-apart positive image of a cat might be viewable by looking through the positive image of the dog depending on if the cat side is powdered differently than the dog side.  
         [0038]    [0038]FIG. 19, which is a top view of a three-dimensional sculpture  410 , illustrates how the process of FIGS. 15-18 can be used to create a three-dimensional sculpture  410  having a positive image  420  and a negative image  430  that are spaced apart from each other to give the impression of depth. If the positive and negative images  420 ,  430  are identical in design, which is created by forming mold halves  320 ,  330  (FIG. 15) from the same surface of the same model (not shown), the resultant sculpture  410  would appear to have an image that is echoed in space. Depending on how each image is powdered and/or colored in accordance with the method described above, each image may be viewable through the other image, creating a unique visual effect.  
         [0039]    Identical positive and negative images may be formed by first creating a negative silicone mold of the image, and then using such negative silicone mold to create a negative casting mold, which negative casting mold will then be used to create a positive silicone mold of the same image. Once the positive and negative silicone molds are created, they are arranged on support molds as illustrated in FIGS. 15-16 to form a three-dimensional model (FIG. 18), from which a powder-laden, three-dimensional sculpture will be formed in accordance with the method described in connection with FIGS. 1-14. It will be appreciated that the creation of the three-dimensional model as seen in FIG. 18, from identical positive and negative images, requires a certain amount of artistic talent, since the “two-dimensional” images must be connected somehow to form the three-dimensional model.  
         [0040]    In other words, if the three-dimensional model is cast in plaster, and each image is representative of a face, an artist may connect the positive image of the face and the negative image of the face with a unique hair arrangement so that the faces appear to flow together. Following such example, FIG. 20 illustrates an artistic rendering of a side view of a three-dimensional sculpture  450  created in accordance with the method of the present invention. A positive image of a face  460  is spatially connected to the negative image of the same face  470  (shown positive through the first face  460 ) by an artistic hair treatment  480 , such hair treatment  480  being created during the model-creation phase illustrated in FIGS. 15-18. If the sculpture  450  were rotated around, such that the viewer were looking directly into the negative image of the face  470 , both faces  460  and  470  would appear to be somewhat negative. If instead a three-dimensional model was creating using two identical positive images of faces, the resultant three-dimensional sculpture would appear to have two faces extending in opposite directions from the same head. If instead a three-dimensional model was creating using three or four identical positive images of faces, the resultant three-dimensional sculpture would appear to have multiple faces extending in various directions from the same head. Thus, the artistic possibilities are endless.  
         [0041]    While the present invention has been described at some length and with some particularity with respect to the several described embodiments, it is not intended that it should be limited to any such particulars or embodiments or any particular embodiment, but it is to be construed with references to the appended claims so as to provide the broadest possible interpretation of such claims in view of the prior art and, therefore, to effectively encompass the intended scope of the invention. Furthermore, the foregoing describes the invention in terms of embodiments foreseen by the inventor for which an enabling description was available, notwithstanding that insubstantial modifications of the invention, not presently foreseen, may nonetheless represent equivalents thereto.