Expanded polystyrene (EPS) is used as the basic structure because it is lightweight and easy to shape into desired shapes, while plaster is applied as a finishing layer to ensure strength and durability. The process usually includes:
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Cutting Styrofoam: Styrofoam is precisely cut into 3D shapes using CNC machines or by hand, depending on the complexity of the design.
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Applying the mesh: A mesh is usually placed on the Styrofoam to help the plaster adhere better and improve structural stability.
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Applying plaster: The plaster is applied over the Styrofoam and mesh in several thin layers. When it dries, the surface becomes hard, resistant and ready for additional finishing coats or paints.
This technique is ideal for creating large themed decorations such as rocks, facades, or sculptures in theme parks because it is relatively fast and allows for flexibility in design.