Hey Everyone,
I ran into a minor problem and I thought I would share my solution with you. As I understand it these forums are useful to not only
get help, but also to
give help. My experience as an orthodontist provided me with an unexpected solution that might be useful to one of you some day.
One of the king/fool castings was flawed:
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The surface is quite irregular and rough compared to the other castings. I could have worked with it - but this painting is challenging enough and trying to recover from a poor casting would have made a hard job even harder.
I determined to make a duplicate of one of the better castings for use as a replacement. I considered several options: I have a 3D scanner in my office that could have made a perfect/detailed digital map - but 3D printing will not reproduce the surface detail at this scale (at least the 3D printers I have available to me). Instead, I took an imprint of a better casting using the same material your dentist uses to take an impression of your teeth for a crown or a bridge.
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I then poured up the mold in plaster (using a vibrating platform to remove any air bubbles in the plaster is essential here).
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The finished product:
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Voila! After trimming up the plaster duplicate(s) I painted them along with the metal castings...
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Which one is the metal original and which one is plaster? I'm declaring this technique a WIN!
Most dentists still use material like this though it is getting less common with the introduction of 3D scanning technology. In a pinch give your local dentist a call and see if they can help you out - it took no more than 30 minutes to fabricate the duplicates.
Hope this might be useful to someone in the future - or prompt you to come up with an even better idea...