Methods and apparatus for replicating original objects

Abstract

Methods and apparatus for producing cast articles with characteristics of original objects such as a stone panel. The cast articles can replicate the contours, textures, and colors of all or a portion of the original object and can be made in any shape or size and specifically can be formed to simulate rock walls, carved stone architecture details, and other construction components normally created by stone masons or sculptors on site and at a high cost. The processes used in making the cast articles include the production of a series of molds. The molds seek to replicate the size, shape, contour, and surface texture of an original object with or without modifications to the original object.

1 . A system for production of cast articles replicating on at least part of the surface of each of the cast articles, a portion of the surface of an original object, said system comprising: a first mold that replicates said portion of the surface of the original object; a master reproduction made from the first mold; a second mold made from the master reproduction; a first conveyor; said second mold being positioned on said first conveyor, said second mold replicating at least part of the surface of the master reproduction; a dispenser positioned adjacent to said first conveyor for filling said second mold with a castable material; and a second conveyor positioned adjacent to said first conveyor for substantially confining said castable material to said second mold.  
   
   
       2 . The system of  claim 1  further comprising at least one color additive dispenser positioned adjacent to said first conveyor for placing a coloring agent into said second mold.  
   
   
       3 . The system of  claim 1  further comprising at least one dispenser of solvent positioned adjacent to said first conveyor for applying solvent into said second mold.  
   
   
       4 . The system of  claim 1  further comprising at least one dispenser of a protective additive.  
   
   
       5 . The system of  claim 1  further comprising a heater for drying said second mold before being filled with the castable material.  
   
   
       6 . Apparatus for production of a cast article replicating on at least part of the surface thereof, at least a portion of the surface of an original object, said apparatus comprising: a first mold replicating at least said portion of the surface of the original object; a master reproduction made with a first castable material placed in the first mold; a second mold that replicates at least a part of the surface of the master reproduction; and a closable support structure having a bottom to support the second mold and a top to cover the second mold.  
   
   
       7 . The apparatus of  claim 6  further including a closing mechanism to place the top against the second mold.  
   
   
       8 . The apparatus of  claim 6  further including a second closable support structure.  
   
   
       9 . The apparatus of  claim 6  further including a pressure mechanism applying pressure to compress at least one of the top and bottom on the closable support structure toward each other.  
   
   
       10 . The apparatus of  claim 6  wherein the top of the closable support structure has at least one vent to allow excess castable material to exit.  
   
   
       11 . The apparatus of  claim 6  wherein the top of the closable support structure protrudes into the second mold.