Abstract: A uniformly expandable mold is formed with a continuous surface defining a three-dimensional pattern for replicating an article. The relative pressure between the inside of the mold and the outside controls the area of the surface to change the size of the three-dimensional pattern without distorting the relative dimensional relationship of the component segments forming the pattern whereby material may be deposited on the mold surface with the mold expanded to a desired size. The pressure differential is increased to increase the size of the mold and stretch the layer already deposited thereon. A second, dissimilar layer is bonded to the first layer while it is streched When the article is removed from the mold, a state of relative expansive/compressive tension is created at the bond interface between the first and second layers which forces the material of one layer to enter voids in the other layer to seal defects.