The improved mold assembly for cultured marble molding is provided. The mold assembly can comprise a male mold portion and a female mold portion. The assembly can further comprise a molding tool. The molding tool can have a side wall having an upper curved portion and a lower curved portion. The molding tool can have a bowl portion and an apron portion spaced from the bowl portion by a gap. The molding tool can be constructed from a flexible and/or soft material. The molding tool can facilitate molding of a countertop having at least one seamless curved edge and/or an at least partially seamless sink portion.
1. A method of molding a countertop with an integral bowl, the method comprising:
providing a male mold portion having countertop mold projections;
providing a flexible insert having a bowl portion having a mold surface and a product surface, the product surface being convex and curved in a first direction and in a second direction perpendicular to the first direction, the flexible insert having an apron portion integral with the bowl portion and spaced from the bowl portion by a gap distance, the apron portion having a product surface facing the product surface of the bowl portion and separated from the product surface of the bowl portion by the gap distance, the product surface of the apron portion being concave and curved in both the first and second directions;
applying a gel coat to the product surfaces of the bowl portion and the apron portion;
releasably mating the mold surface of the bowl portion to the male mold;
providing a female mold portion having countertop mold recesses;
releasably mating the female mold portion to the male mold portion such that the flexible insert is positioned between the female mold portion and the male mold portion, a space between the mated female mold portion and male mold portion defining a mold volume;
backing the gel coat with a composite matrix material into the mold volume, wherein the composite matrix material solidifies after a setting time to form a countertop having at least one of a seamless front side and a seamless side end;
unmating the female mold portion from the male mold portion after the setting time has taken place; and
removing the flexible insert from the countertop.
2. The method of claim 1 , wherein the countertop having at least one of a seamless front side and a seamless side end comprises a sink portion having a rim, the rim having a thickness substantially equal to the gap distance.
3. The method of claim 1 , wherein the gap distance is less than twelve inches.
4. The method of claim 1 , wherein the gap distance is approximately three eighths of an inch.
5. The method of claim 1 , wherein the countertop is a cultured marble countertop.
6. The method of claim 1 , further comprising removing the flexible insert from the male mold portion.
7. The method of claim 6 , wherein the flexible insert is removed from the countertop after the flexible insert is removed from the male mold portion.