Creating Faux Bronze Plaque with lightweight PU Foam

This short video shows the process of making a faux bronze plaque using a technique called cold-metal casting. First a silicone mold is made from a real wood plaque. Once you have the mold, bronze powder is dusted into the mold and a thin layer of fast curing polyurethane (TC-808) is applied behind the powder. Next, a batch of 6 pound rigid expanding polyurethane foam is cast behind the first layers of material to form a strong, lightweight part. Lastly, the part is demolded and the bronze powder surface is burnished to produce a realistic metal surface.