Jesmonite AC730 Flex Metal -Gel Coat-

Jesmonite AC730 Flex Metal Gel Coat is a metallic finishing layer formulated with real metal powders that, applied inside the mould before laminating with AC730, produces surfaces with the look and feel of genuine metal. It is based on water-based Flex Resin technology, with no solvents or VOCs, making it one of the safest options on the market for metallic replicas in acrylic composites.

Technical specifications

What it is used for

This gel coat is designed to create replicas of metal parts with an authentic finish without resorting to solid metal or galvanic techniques. It is applied as the first layer inside the mould before the structural backing, and the final result can be worked exactly like real metal.

• Decorative replicas of metal parts: frames, mouldings, sculptures and reliefs
• Props and set dressing for film, television and theatre with a metal appearance
• Interior decoration: panels, cladding, columns and architectural elements
• Reproduction of industrial or artistic pieces for display or replacement
• Furniture and decorative accessories with a metallic finish
• Prototypes and scale models with the appearance of cast or forged metal
• Restoration of ornamental elements when the original metal piece cannot be replicated in metal

How to use it

1. Prepare the mould (silicone or similar), making sure the surface is clean and, if necessary, apply a suitable release agent for water-based acrylic materials.
2. Weigh the components: between 5 and 6 parts base (metal powder) to 1 part acrylic liquid, by weight. Adjust within that range to achieve the desired consistency.
3. Mix manually with a spatula or paddle mixer until you obtain a smooth, lump-free paste. If you need more working time, add Retardante Acrystal.
4. Apply the gel coat with a brush or spatula onto the mould surface in a uniform layer of approximately 2–3 mm. For vertical or inclined surfaces, add Tixotropante Acrystal to prevent sagging.
5. Allow the gel coat layer to gel until it is firm to the touch but not fully cured through.
6. Apply the structural backing of Jesmonite AC730 as a fibre laminate or as a direct casting over the gel coat.
7. Allow the assembly to cure for the time needed until the piece can be demoulded.
8. Demould carefully and proceed to finishing: rub the surface with fine steel wool by hand to reveal the metallic sheen, or use a polishing machine with metal-specific heads.
9. Apply wax, sealer or patina according to the desired final finish, exactly as you would on real metal.

Usage tips

Adjusting the ratio to achieve the desired effect

A 5:1 ratio (more powder) produces a denser layer with a higher metallic concentration at the surface, which makes polishing easier and delivers more shine. At 6:1 (slightly more liquid) the mix is more fluid and penetrates finer mould details more effectively. Test with a small amount before tackling the full piece; the four available finishes (Brass, Bronze, Copper, Silver Bronze) can be blended together to extend the palette. If you are not sure where to start, the Jesmonite Flex Metal sample box lets you test all finishes before buying in bulk.

Polishing to reveal the metal

The most realistic result is achieved through polishing. Using extra-fine steel wool (grade 0000), rub in circles over the cured and demoulded piece: the metal powders at the surface will emerge and create a burnished metal effect. On relief areas, selective polishing generates contrast between bright and matt zones that mimics the natural ageing of metal. If using a polishing machine, start at low speeds to avoid removing material.

Patinating and final protection

Once polished, the piece accepts the same treatments as real metal: carnauba or paraffin waxes to protect and add lustre, transparent acrylic sealers for outdoor use, or acid-based patinating agents to create oxidation or ageing effects. Flex Metal also accepts acrylic pigments mixed into the body to add background tints that modulate the final metallic tone. Experiment on samples before applying to the finished piece.

Frequently asked questions