Molding & Casting Services
Custom Silicone Molds, Master Patterns & Precision Resin Casting
Kemperle Industries provides custom silicone molds, 3D master patterns, and professional resin casting services for clients who need high-fidelity, repeatable parts — from aftermarket automotive components to fine art fabrication and ornamental plaster reproduction.
Our team designs and fabricates production-ready tooling, enabling consistent casting in a variety of materials for architectural details, heritage restoration, experiential builds, and limited-run objects.
Ideal for:
- Short-run production (10–500+ pieces)
- High-detail replication
- Architectural & ornamental reproduction
- Aftermarket automotive components
- Retail & experiential installations
- Fine art and limited edition objects
What We Provide
Custom Silicone Mold Fabrication
We design and build custom silicone molds engineered for repeatability, surface fidelity, and efficient production.
Every mould for resin casting is developed around the specific geometry, material, and production volume of your project.
Our mold fabrication capabilities include:
- Multi-part silicone molds
- Complex undercut management
- Registration keys and alignment systems
- Venting and air-release strategy
- Reinforced mold construction
- Tool life planning
Proper mold design is what separates reliable resin casting molds from inconsistent reproduction. Our process prioritizes durability, dimensional stability, and clean part release.
Ornamental Plaster & Decorative Replication
We regularly produce complex 3D master patterns for ornamental plaster, historic architectural elements, and decorative components, specifically engineered for mold making and repeatable casting.
Typical projects include:
- Cornices and crown details
- Ceiling medallions and rosettes
- Relief panels and moldings
- Decorative façade elements
- Restored plaster originals
When original geometry is incomplete, fragile, or inconsistent, our team can generate a precise digital model and fabricate a high-fidelity master pattern optimized for clean mold release and dimensional stability.
For heritage projects, we can begin from a physical artifact or from high-resolution 3D scanning data when originals must be preserved.
Professional Resin Casting
Once tooling is complete, we produce controlled, repeatable resin casting runs using production-grade materials.
Rigid Resin Casting
- High-detail rigid urethanes
- Structural and decorative components
- Smooth or textured finishes
Flexible Resin Casting
- Elastomeric urethanes
- Impact-resistant parts
- Rubber-like components
Clear & Specialty Resin Systems
- Transparent cast parts
- Tinted and specialty finishes
- Heat- and UV-resistant options
Filled & Composite Castings
- Stone-effect resins
- Metal-look finishes
- Reinforced systems
Not sure what is the right path for your project?
We help clients choose between molding, 3D printing, machining, or hybrid workflows.
If you need a digital master first, explore our 3D Scanning Services or Reverse Engineering Services.
If direct digital production makes more sense, see our 3D Printing Services.
Our Process
Our process is designed to produce consistent, high-fidelity parts from the first piece through full short-run production.
Master Pattern Preparation
We begin with a master pattern provided by the client or developed in-house.
Typical starting points include:
- Physical originals
- Restored legacy parts
- Reverse engineered CAD models
- CNC machined masters
- 3D printed masters
The quality of the master directly determines the quality of the final resin casting.
Mold Design & Tooling
We fabricate custom silicone molds tailored to your geometry and production goals.
Our team evaluates:
- Parting line strategy
- Undercuts and release
- Mold durability
- Shrinkage considerations
- Batch consistency
Each mould for resin casting is engineered to support predictable, repeatable output.
Batch Casting Production
With tooling complete, we run controlled casting batches with attention to:
- Material consistency
- Surface fidelity
- Insert placement
- Dimensional repeatability
Typical silicone tooling supports dozens to hundreds of parts depending on geometry and material.
Finishing & Assembly
Post-processing options include:
- Flash trimming
- Surface preparation
- Paint and coatings
- Metallic and specialty finishes
- Hardware integration
- Final assembly
Parts leave our shop ready for installation or deployment.
When Resin Casting Is the Right Production Method
Resin casting molds are often the best solution when:
- You need repeatable parts without injection tooling
- Surface detail must be preserved
- Production volumes are moderate
- Material realism is important
- Geometry is complex
For one-off parts, 3D printing may be more efficient. For very high volumes, injection molding may be appropriate.
We help clients evaluate these decisions early, where cost and quality are most affected.
Typical Applications
Art Fabrication & Limited Editions
We support artists, studios, and fabricators with production-grade resin casting for:
- Editioned sculptures
- Complex organic forms
- Large-format segmented casts
- Material and finish experimentation
- Gallery and public art fabrication
Ornamental Plaster & Architectural Restoration
High-detail custom silicone molds allow fragile or historic originals to be reproduced with minimal risk to the source object.
- Ornamental plaster replication
- Historic cornices and medallions
- Decorative architectural details
- Museum-quality reproduction
- Lightweight replacement components
Aftermarket Automotive
- Interior trim reproduction
- Decorative components
- Legacy part duplication
Retail & Experiential
- Sculptural elements
- Custom awards
- Branded display objects
- Lightweight scenic components
- Arcade game parts
- Custom props & merchandise
Frequently Asked Questions
How many parts can you make from a silicone mold?
Many resin casting molds support dozens to hundreds of parts depending on geometry and material. We evaluate expected tool life during quoting.
Can you create molds from 3D printed parts?
Yes. We regularly fabricate custom silicone molds from printed masters, machined parts, and physical originals.
What materials can be used for resin casting?
We offer rigid and flexible urethanes, clear systems, and specialty filled resins depending on performance needs.
Can you match the appearance of the original part?
In many cases, yes. Our resin casting process is designed to preserve fine surface detail, and we offer a range of finishing options including paint, metallic effects, and specialty coatings to closely match the original appearance.
Do you work with artists, fabricators, and architects?
Yes. We regularly support art fabrication studios, ornamental plaster specialists, architects, and experiential teams who need reliable resin casting molds and repeatable production.