img 02Industrial Carving Services can create single use or multiple use moulds to suit your individual requirements.

Where moulds are required to be used multiple times, they are often made from silicone rubber and are produced from a polystyrene pattern or plug. Polystyrene is ideal for the purpose because it is light, economical and a high level of accuracy is available in its machining.
Male or female mould surfaces can be extracted from an electronic model and enhanced to make provision for parting lines, alignment dowels and trim allowances. Once the mould design is completed, the piece is machined from blocks of medium density polystyrene foam. The machined polystyrene is then filled and sanded to produce a smooth surface. After smoothing, the polystyrene is coated with a thick polyurethane hard coating which protects the foam, makes the mould rigid and provides a lightweight support structure. The hard coat provides an excellent surface for fibreglass release agents.
Single use moulds can also be created quickly using polystyrene and are ideal for casting words, numbers or artistic elements to add interest to plain surfaces or to create unique standalone features.

EXAMPLES

Sound Walls on Brisbane’s North South Bypass Tunnel
This project called for the manufacture and installation of sound barrier walls featuring textured wave patterns repeated every third panel. ICS was supplied with panel detail drawings, and produced polystyrene foam panels suitable for the client to produce rubber moulds in which three different precast concrete sound wall panels could be manufactured.
Each of the finished patterns measured 4000mm x 2400mm.
Specifications called for a textured pattern on the top wave, a smooth finish on the middle wave and corrugations along the bottom section. For the top wave, the texture was created by scanning a sample of 20mm aggregate, scaling it up by 50%, limiting the depth to a maximum of 15mm and then applying this texture to the area specified in the drawings.
The finished panels can be seen at the Ipswich Road entrance to the tunnel at Woolloongabba.

Fan Shroud  

 

To see more examples of our work, visit the image gallery - click here

Products & Services

Artwork & Sculptures
Products

Artwork & Sculptures

We are regularly commissioned by artists and graphic designers to convert their Clay Marquettes or complex 3D electronic creations into the physical form.

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Architectural Products
Products

Architectural Products

Polystyrene foam can be carved to create one-off architectural features or to create large and complex fibreglass moulds for the production of multiple objects.

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Commercial & Industrial
Products

Commercial & Industrial

Industrial Carving Services can create single use or multiple use moulds, suitable for Fibreglass or Pre-cast Concrete, to suit your individual requirements.

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Trains, Planes & Automobiles
Products

Trains, Planes & Automobiles

We have included this tab to show the diversity of our customers’ requirements. It is truly a case of what we can make is only limited by imagination.

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Signage & Exhibition
Products

Signage & Exhibition

The light weight, versatility and low cost of polystyrene foam make the material ideal for signage, stage props and trade display themes.

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Foam Cutting
Products

Foam Cutting

Many customers’ requirements can be satisfied using our computer controlled (CNC) hotwire cutting equipment in lieu of the more costly and time consuming 3-axis carving techniques used for more complex model

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3D Scanning & Design
Services

3D Scanning & Design

Much of our work comes in as electronic 3D models but where an electronic 3D model doesn’t already exist we can 3D scan a customer’s sample to develop the electronic model required for computerised carving..

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Need More Information?
Services

Need More Information?

If you have a modelling requirement, we can help We have a online form to help you make an inquiry..

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