woodezine - Volume II - Issue VI - June 2004

Photo courtesy of Century Architectural Specialties
 

why on earth would a
woodworking magazine
have a feature on..
.

urethane
moldings


Tom Banwell offers one answer. His company in Penn Valley, California offers custom resin casting in both urethane and polyester, using silicone rubber molds. Tom also offers classes on making resin castings and molds. He is an acknowledged expert in making resins look like wood - see the resin reproduction of a woodcarving (below right), showing the "grain" of the wood. A page on his Web site (http://www.lumicast.com/wood.html) begins with...

Resin can be made to resemble wood, duplicating every chisel mark in a carving. End grain, cracks, and the open grain of oak all come out looking just like the real thing. Natural pieces of wood with or without bark and driftwood are also easily reproduced. Wood stains, antiquing and paints can be used to enhance the look.


Copyright ©1987 Tom Banwell
 

Making plastics look like wood has been a constant theme in the moldings world for a very long time. Witness the excellent ceiling medallion from Century (shown above), with a faux chestnut finish which blends beautifully with the wood ceiling above it. Or the detail from Tom Banwell's "Sunface" at left.

 

 

 

Mixed Media
Applying a wood finish to moldings - to make them match the natural elements in a project - is certainly a viable option for woodworkers. But it isn't the only one. Urethane moldings, especially architectural pieces, can be used extensively in the woodshop - as accents on furniture and cabinetry, in frames and fireplace surrounds and hundreds of other applications. The finish doesn't have to be purist. It can be stained, painted or dyed to a myriad tones and still work well with natural grains. Using precast corbels or other elements is a very economical way to add fine architectural detail to a project. Take, for example, a couple of corbels like the one shown at left. If they were ebonized (painted almost black), or even painted to match the trim color in a room, and then used to support a thick maple shelf, the opposing textures could be quite dramatic.

It's even more fun to think about using one of the newest twists in urethane moldings - Formaflex (TM). This is a series of flexible moldings from Century (shown at right) which follow a curve or arch.

Aside from the design possibilities presented by precast, extruded or flexible moldings, there are a few other reasons to consider using urethane products. For one, the cost can be quite a bit less. Uniformity is another factor - these moldings are engineered, not grown, so the intervals between the teeth in a dentil molding will all be absolutely uniform. And defects are virtually eliminated - annoyances like splitting, cracking, splinters, warping and even rotting. Plus, you don't have to sand them, which on its own is enough to make this old woodworker take a second look.

 
  Choices
One of the biggest upsides to urethane and similar moldings is the huge variety of profiles available. While much of each manufacturer's catalog is devoted to tried and true classical moldings based on Greek and Roman architecture, some of the best companies have extended their repetoire to include elements of American and modern European architectural cultures. Colonial and Federal artisans took classical forms to a new level and produced in cast plaster what might not have worked so well in the original carved marble.
Contemporary manufacturers are now nurturing that evolution with wonderful moldings like the bent crown from Style Solutions, shown at left, above. Such innovative engineering presents woodworkers with a whole new palette of materials and options. If, after a visit to the sites mentioned here, you decide to take the plunge and add this resource to your own work, please let us know.


Click on the image to visit their site

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