Polystyrene Arc Spraying
Metal spray coatings can be applied onto all sorts of surfaces including, but not limited to: polystyrene, polyurethane foam, rubber silicon, wood and even apples!
Polystyrene Zeus Head (Left), Bronze Coated Zeus Head (Middle), Polished Bronze Coated Zeus Head (Right)
Polystyrene is widely used for props in performing arts industries on movie and theatrical sets. Metal Sprayed coatings using the Arc Spray process are ideal for polystyrene props, providing the structural integrity required for props, without compromising any of the surface detail. Metal spray solidifies immediately on hitting the surface with very minimal heat, causing no deformation. Metal spray coatings are perfect protection for polystyrene as they add only minimal weight to the finished subject.
There is no limit to the size of job to be completed with the Metal Spray process, making it perfect for all shapes and sizes of props. Coatings can be applied in desired thicknesses, the thicker the coat the stronger the structure, however, thicker coatings will add a little extra weight to the finished product.
Different types of metals can be sprayed such as Bronze, Zinc, Steel and Brass. Metal Sprayed surfaces can be polished or painted as required for prop completion.
Polystyrene Mannequin Head (Left), Polished Arc Sprayed Zinc Mannequin Head (Right)
A 3D map of the world was created for part of a movie set. The map needed to be strong enough to take the weight of the actors who would be walking on it during filming. This strength and durability was provided by the metal sprayed finish.
Metal Spraying of a Polystyrene Map of the World (used as part of a movie set)
Another example has seen polystyrene shaped as books, then used for a library scene. These books were then metal sprayed for durability and painted to look like a row of books. Different coloured metals and materials can be used to offer a range of finishes. Post spraying techniques, such as polishing and acid ageing are available.
As well as being used on polystyrene, metal spraying can also be used to spray onto fibreglass, rubber silicon, polyurethane foam and carbon-fibre mouldings for decorative purposes.
Zinc helmet produced using a rubber silicon mould
