Behind the Scenes: The Craft of Casting Statuary

Kenneth Lynch and Sons began casting statuary from latex rubber molds in the 1950s. From the early days of latex molds with plaster outer shells we have perfected the practice. In this example, we are demonstrating the process for creating our “Mermaid Boy Riding a Fish”, an original sculpture by Anne Kopper, which has wonderful sculptural details in his hair and scaled legs.

Casting is the process of making a mold and then pouring in liquid material for producing statuary of cast stone. At Kenneth Lynch & Sons, our process includes the application of multiple layers of brush applied latex, mother mold or shell of hand applied resin and fiberglass, and mold set up for casting. The final step is the de-molding process of a freshly cast piece that ultimately reveals a beautiful cast stone figure.

Over time, molds that are used for casting will wear out - some due to high use, and others due to deterioration over the years. If you take a look at our enchanting model of a merman riding a fish, it is surprising to many that this one mold had been used to create the same cast stone piece for over 50 years! However, the surface of the latex mold had become gummy and no longer produced a crisp casting. Thankfully, we have the good fortune of owning most of our original models which makes it possible to replicate the same product even if the original mold has deteriorated.

After touching up some of the slightly damaged areas of the original plaster, the model is ready for mold making. We apply latex in multiple layers over a course of days until the desired thickness is achieved in order to pick up the fine details of the model. The latex remains very pliable and requires a hard shell to back it up and keep its shape. The hard shell can be made of plaster or fiberglass, fiberglass is more durable and also keeps the mold to a more manageable size therefore it is our choice as the hard shell.

Finally, the mold is ready to be stripped out and prepared for casting! This model is plumbed as a fountain spout. Our shop prepares copper tubing to be placed inside of the casting. Our cast stone mixture cures overnight allowing for removal of the hard shell and latex the following day. After a cure of at least 7 days our team smooths the parting seam and hand applies a cement slurry to fill any surface air pockets. The copper tube is shaped into a spout and the piece is ready for its new poolside home!

Many thanks to our client Jim Ohlenburg, Ohlenburg Inc, of Dallas, Texas who specified this delightful figure for his client’s project. As seen here, the fish has been plumbed as a fountain feature, perfect for poolside enjoyment!

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Human Statuary
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