When the design is finished, Rob must assemble the first model from scratch. 

This model must be exactly how the finished piece will look, as it will be used to make the rubber mold.  A great deal of hand work can go into making the model.  As mentioned in the previous step, Rob's models are always made in metal, not wax, which lends the distinctive sharpness to his designs.

 

In relatively flat pieces such as these earrings, the first step is piercing out the shape of the piece from a sheet of silver. A paper pattern is glued down to act as a guide, and each opening is carefully cut out. Then a variety of hand- and power tools are used to smooth rough edges, even curves and cut interlace, with checks at every stage for accuracy and consistent form - doubly so in cases like this where two pieces must have identical elements!

Finally, a rod called a sprue is soldered onto the model to prepare it for molding - we'll see why in the next step. Even here, careful consideration is a must, as where there is a sprue on the model, there will be one on the casting; it must be placed so that it will allow the piece to cast completely and still be easy to remove later on.

Start Over -- Previous Step: Sketching & Design -- Next Step: Molding & Drawing Waxes