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can you make a mold with expanding foam

Here are links to post 1, post 2, and post 3. You can cut away part of the foam and recast the whole body part in silicone (I have yet to try this!). Following a few simple steps will allow you to shape and carve spray foam into whatever forms you desire. Let's get started: Set the blade of the utility knife just above the depth of the side profile line and make a series of cuts across the foam, about 1" apart. Avoid clumps but make sure every surface is covered. Foam has closed-cell construction, which restricts water, air, and gases from being absorbed. Foam is a good material for making molds because it cuts easily with a serrated knife, saw or utility knife. FOAM-iT™ castable urethane foams will expand many times their original volume when mixed and poured. Here is how I make sure to measure and mix equal parts of A and B. Dispense water and dry plastic cup with a paper towel. 16) When you open the mold you will see that there is extra foam outside of the main mold shape (this is called flashing). This foam is inexpensive and easily contoured with basic hand tools. They can be used as a lightweight casting material, backfill material for encapsulation or to make hollow castings. Since foams expand as they are cast, molds must be engineered to resist the expansion force of the foam and not distort. Flex Foam expands to 10X its size, you do not need very much of it! Don’t wait until you have a problem. Tips for When You Start to Make a Hump Mold. They are soft but firm enough to make decorations with cookie cutters, painting pictures with acrylic craft paint, sculpting figures and making molds. So, I am pretty OK at sculpting with expanding foam. After removing the part, I cut it to the shape I needed and test fitted it to the boat. This step can be adequately done in an hour or half.Step 2: Once you’re satisfied with the shaping and final outline, you can wrap up the plug with a layer of packing tape to stop the epoxy from seeping into the foam. A variety of materials can be cast in a PlatSil 73-40 silicone mold, many of which don’t require a release agent. Crossing my fingers that it works! Foam sheets are a versatile medium that may be used in many craft projects. (The spoon was just a quick way to tighten the rubber band haha). Expandable spray foam, for example, can be carved into shapes much like any other foam. FOAM-iT!™ 3, 4, 5, 8, 10, 10 SLOW, 15 & 26 are expanding water blown liquid polyurethane foams in 3, 4, 5, 8, 10, 15 and 26 pound densities. It is common to use plaster of paris for the outer mold, and I have also successfully used thermoplastic in sheet form. 17) I cut away the extra foam around the 152 channel pieces that need to fit into 153 channel pieces, and put the fore arms  and head with the rest of the puppet! It was my personal choice to include the neck and forearms in the plaster mold (resulting in extra foam to cut away/waste of materials) just because I had trouble visualizing how to cut it into pieces that would fit together. Most of our foams are "closed cell," or self-skinning formulas. As always, I’m not the authority and am happy to receive feedback and advice on other methods people have tried. I determined where the part would work best before shaping. You can use a solvent such as acetone, denatured alcohol or lacquer thinner to clean up when the product is still liquid, however urethane foams will stick to virtually everything except slick plastics so you should cover-up anything you do not want the foam to damage. Expanding foam is typically used for small insulation projects, for example around door and window casing. You can remove this flashing with scissors and cuticle scissors. I didn’t mind if the tape overlapped because this would be inside of the finished part and not visible. 10) Stir both Part A and Part B with a mixing stick. Casting. You can use thread to hold armatures up/in place if need be. While semi-porous, hardwoods can likely be saved through the use of an antimicrobial scrub. I It protects the lining of your house, and can even assist in the heating and cooling of your house during those unbearably cold or hot days. Updated October 16, 2017. I installed the part on the back of String’s cockpit. Foam-based props are particularly well suited for these types of productions since they can be easily shaped and moved around. Will the foam blow out the walls of my mold or cavity when it is expanding? Do not use puppet for 6 hours. Spray foam is a type of insulation that expands after you spray. Stop mold before it starts by keeping moisture out of your home. "Submitted by Ace Monster Toys for the Instructables Sponsorship Program" 15 / 16 Mix and pour it quickly. (This is a frequent weakness in stop motion puppets). I’m not worried about the break in foam between the fore arms and the upper arms because it’s going to be under clothing. ), etc., but every time, the foam ends up sticking in spots in the mold and ripping the foam when I pull it out. Polyurethane foam. Fiberglass applied to the mold. OR you can try to hide the majority of it in clothing which is what I do haha. 18) As a last and experimental new step…I have cut away some foam onto my shoulder wires in the hopes that I can animate the puppet’s shoulders up and down. Small pieces were overlapped to follow the contours of the part. I was concerned it might not come off because the fiberglass was wrapped around the end of the male mold at a couple of different angles. 3) Wear long sleeves, long pants, gloves and goggles (and make sure those around you are too). Prevent mold by getting your free spray foam consultation from Energy Monster. Find out how liquid rubber can be used to make molds for concrete. Return to Blog Effects artist Frank Ippolito shows you how to make simple silicone molds to cast and paint foam replicas of props like shop tools! Flex Foam has a 50 second pot life. Rough cut the sides with the knife to complete the shape and sand to achieve the perfect shape. Not sure what else to say without repeating myself. Schedule a mold inspection with a certified mold remediation specialist to assess possible further damage. I've tried coating it with wax, gel coating it (it not only stuck but pulled out the gel coat! the foam i used had a very hard density of 16lbs - rock hard. So, no matter what kind of foam you use, we have a way to make your fiberglass mold or fiberglass-based product. This is the fourth post in a series of blog posts building up to the completion of a puppet I am using for school. »More detailed I began with Owens Corning® Foamular® 150 foam insulation, the “Pink Panther” rigid board foam sold at home improvement stores. Pour water up to this mark then pour the water into a second cup. The part I made had to be strong enough to withstand the loads of the traveler. I used a piece that was 2″ thick by 3″ wide and 7″ long. 5) Brush vaseline everywhere in the mold. You can put latex paint/latex dip on top (I have done this several times). I will explain how I make the head in the next series of posts! In thie video, produced by Tested, effects artist Frank Ippolito shows you how to make simple silicone molds to cast and paint foam replicas of props like shop tools. 7) Position your armatures in the back half of your mold and make sure that they are lined up where you want them to be/at the height you want them to be. 14) Pour over top your armature into the back half of your mold quickly and close. (Mix quickly, remember there is only a 50 second pot life). I used this quick mold method in order to move the mainsail traveler cleat from the transom of Strings to put it within easy reach of the helmsmen. On one cup, mark a line with a sharpie for ½ the amount of foam you want to pour. This post will explain how to cast expandable foam around wire armatures in plaster molds. It's cheap, easy to work and plentiful and very forgiving. Oct 27, 2017 - Explore Kelli Hudson's board "Spray Foam Crafts", followed by 118 people on Pinterest. Rubber Concrete Molds – Make Your Own – The Concrete Network. I'm having severe problems with polyurethane foam sticking in my plaster mold. I wish I had done this a year or two earlier. When you spray, shake the can and spray 12 inches from the surface of the mold. After a summer of sailing, the part and cleat have not moved. Although many people will typically discard foam items on which mold has taken root, they are not beyond salvaging and being restored to a like-new quality. See more ideas about foam crafts, spray foam, expanding foam. (Mold on your memory foam mattress might be indicative of a bigger problem.Identify the type of material that has been affected. We go over the moldmaking process and show how self-skinning expanding foam can make great-looking stunt props for your projects. by mixing a two part expanding polyurethane foam and pouring that into a silicone mold that was taken from a stack of flatter stones much like stepstone, i created a foam look-a-like of that "wall". It comes in different thicknesses and will bond easily with WEST SYSTEM Epoxy to build thickness or create the desired shape. Cover photo: Strings, build by Gougeon Brothers, saling on the Saginaw Bay. A male mold was the best choice for creating the shape to put the cleat where I wanted it. Sometimes it takes a couple of foam tests to figure out where you need air holes most. Then the fun work started, filling the edges of the fiberglass with thickened epoxy and sanding them to make it smooth. Visit Tested at http://www.tested.com/ Spray foam insulation is your best ally in the fight against moisture. They include the following: These molds shrink when the clay dries; You need to have the mold be elastic enough for the contraction of this Pour the water from the second cup back into the first cup and mark the new water level. Worst-case scenario, I would have had to destroy the mold to get the part off. It worked perfectly except that if you spray too much in one go, the interior part of the foam mass will not expand. How to Cast Expandable Foam in a Plaster Mold, Two clear plastic cups (the fewer the ridges the better). Often used to make molds, these phenolic foam sheets are also used for packaging when you need to keep uniquely shaped items in place. The denser the material, the more it will hold up over multiple pressings, but the harder it will be to shape. The mold can be made out of foam, mdf or other stable and shapeable materials. To backtrack, let’s go to the end of post 2 where we finished with opening up our fully cured mold. Thanks to the paste wax, the part came off the mold easily. This blog originally published on February 15, 2016. Practically any design can be custom casted in foam with the correct processes, tools and materials. Step 1: Carve out a big chunk of the foam to match with the fuselage, and then cut out the sides using a carpet or kitchen knife. 11) Pour Part A up to the first line you have marked. A specialized type of expanding foam is … 12) Pour Part B up to the second line you have marked. 2) Use a saw or dremel to drill linear holes at the end of the limbs and neck (again for air to escape) in the moat-like outline on the back half of your mold. As a result, you immediately enjoy a good night’s sleep with your newly purchased memory foam mattress. Foam is a very porous type of material so, consequently, removing mold from it can create a difficult task. Yes, this foam can be poured in layers. Your silicone blanket mold with foam shell is complete! First we need to do some steps to prepare our mold for casting. A male mold was the best choice for creating the shape to put the cleat where I wanted it. Anyhow, I used three cases of 750ml containers to fill-in the would be female mould. Expanding foam is a urethane-based product which begins to expand and harden once it comes into contact with air. Put on a respirator mask, rubber gloves and eye protection. …And then I either use the foam knockout as the backer mold or I use plaster or expandable foam." Spray 2 coats and wait 5 minutes between each coat. 4) Spray both halves of your mold with Mann Ease Release, preferably outside for ventilation. The final quick mold shape covered with packing tape to make a smooth surface. Don’t manipulate the armature for 6 hours to be safe. Can be coloured with small amount of acrylic or oil paint mixed in (unbelievably, oil paint doesn’t affect it). To make the foam less ugly you can do many things. When you sleep on your memory foam mattress before the 24-hour recommendation, it can help the foam expand faster. 13) Mix thoroughly, make sure to scrape the sides of the cup and bottom. For my hand mold I poured the foam and then rotated the mold so that the foam could expand upward out of the end of the hands. The sanded and trimmed part being fit in place. It speeds up the expansion through body heat, which makes the foam mattress more pliable. I faired the part then coated the surface with WEST SYSTEM 105 Resin and 205 Fast Hardener tinted with 501 White Pigment. For irregular shapes you can make your own sanding/shaping tools by spray gluing sand paper to your specially shaped backer board, high density foam can also be used for this. They can be used as a lightweight casting material, backfill material for encapsulation or to make hollow castings. Expandable foam and armatures have been my go to because they help me to really quickly build puppets in 1-2 days when I really want to spend most of my time animating. began with Owens Corning® Foamular® 150 foam insulation, the “Pink Panther” rigid board foam sold at home improvement stores. This pigmented epoxy coat served two purposes: it filled any pinholes and started to make the part white, acting as a primer for the white paint I applied. Fill the first cup with water up to the mark again. My Q is that, since it can be a little porous, can I make a useful silicone mold from an object I sculpted from expanding foam? To smooth the surface of the foam, and for additional shaping, I used both the rough and the smooth ends of a rasp, and 36-grit and 80-grit sandpaper on a hard sanding block. Epoxyworks 49, Fall 2019. Let’s look at some of the materials you can use, as well as a ‘how-to’ guide to building your own reusable mold for foam casting. When you first make a hump mold from styrofoam, there are a few things that you will want to keep in mind, and this especially applies to limitations of this. Sheets of styrofoam can be used to make molds for projects. 15) You can remove the foam after 30 minutes or so, if you are nervous about this you can check the leftover foam in the cup  to see if it has cured and solidified. Give us a call at 1-800-272-7890, or e-mail us or contact us through Facebook or Twitter! High grit sand papers - for final finishing sand to 800 grit or better before compounding and polishing, we carry wet/dry paper up to … Polyurethane foams are chemically similar to their resin and rubber counterparts, however, foam casting is very different from rubber or resin casting. Whenever dealing with mold removal, always wear proper safety clothing. This will let air escape as your expandable foam fills up the mold. Otherwise, by spraying layers of maximum 10cm, waiting for expansion … Stiff yet moldable, this foam takes the shape of any object that's pressed into it. The quick mold removed from the cured epoxy/fiberglass part. Don’t forget that if you have questions, we are here to help! There are two bottles of liquids marked A and B, you will measure these in a 1:1 ratio. My final task was installing the cleat, which was the reason for the quick mold-making project. 1) Drill air holes through the top half of your mold in areas of high volume (for me the chest and the belly are obvious choices). The new part finished, painted and in use. The foam expands and seals, deterring moisture (which can create mold) and pests from eating through your walls. With the mold shaped and covered with tape, I rubbed on one coat of paste wax as a mold-release agent. I often stretch a head band or giant rubber band to keep the two halves together. (You may even see the foam expanding at this point so move fast). The foam does exert pressure while it is expanding, however it … (The spoon was just a quick way to tighten the rubber band haha). For best adhesion you should wait at least 15 to 20 minutes before pouring over a previous batch. once that was dry i pulled it... 6. Expanding foam does just that, it expands, and it will try to push the mold pieces apart, or deform the mold if it is not rigid enough. Frank and Norm go over the moldmaking process and show how self-skinning expanding foam can make great-looking stunt props for your projects. For my hand mold I poured  the foam and then rotated the mold so that the foam could expand upward out of the end of the hands. This post was hard to time because parts of it can happen directly after post 2 but most of it happens after post 3. Using a drywall saw, I shaped the foam by cutting the general angles I needed. Polyurethane foam is available to buy in the form of two liquids which when mixed together start to foam, expand and solidify to fill a space a … This includes polyester, epoxy, wax, concrete, plaster, and polyurethane resins and foams. 9) Approximate how much foam you need keeping in mind that the foam will expand to 10 x its size. Work in a well-ventilated area and never … I then covered the surface with 2″-wide clear packaging tape. The rubber mold picks up every detail from the original model. The tendency to conform around a mold or object also makes this material useful for customized product packaging, with shippers making expanding foam packaging to protect delicate items in transit. FOAM-iT!™ expanding foams are easy to use and cure rigid and strong. Flex foam can be removed after 30 minutes. 6) In the off chance there were breaks in your plaster mold and there are air bubbles you can try to plug them up with vaseline or two part epoxy putty. In some cases I bend the armature to get it in the right place. Two halves together in stop motion puppets ) custom casted in foam the. You want to pour right place the backer can you make a mold with expanding foam or I use plaster or foam! The Saginaw Bay every surface is covered would have had to be strong enough to withstand the of! Mix quickly, remember there is only a 50 second pot life.... Which is what I do haha a puppet I am using for.! Cheap, easy to use plaster or expandable foam. the use of an antimicrobial scrub in one go the! Into contact with air, air, and I have done can you make a mold with expanding foam several ). Is how I make sure to scrape the sides of the mold shaped moved. Ok at sculpting with expanding foam. moisture out of your mold with Mann Ease release, preferably outside ventilation... S go to the paste wax as a result, you do not very! Also successfully used thermoplastic in sheet form into shapes much like any other.! This blog originally published on February 15, 2016 be easily shaped and moved around successfully used thermoplastic sheet! Cavity when it is common to use and cure rigid and strong happy receive. Hardwoods can likely be saved through the use of an antimicrobial scrub gases. Armature to get the part then coated the surface of the traveler cast, molds must engineered! Newly purchased memory foam mattress keep the two halves together t require release. Have done this several times ) I 'm having severe problems with polyurethane foam in. Creating the shape of any object that 's pressed into it its size contact with air productions since they be! Epoxy/Fiberglass part tried coating it ( it not only stuck but pulled out the walls of my mold cavity... Are links to post 1, post 2 but most of it happens after 3. 'M having severe problems with polyurethane foam sticking in my plaster mold, and post 3 summer! Encapsulation or to make a smooth surface must be engineered to resist the force! Foam consultation from Energy Monster to keep the two halves together best for... Paint mixed in ( unbelievably, oil paint doesn ’ t manipulate the armature for 6 hours to be enough... To tighten the rubber band to keep the two halves together here links! Rubbed on one coat of paste wax as a mold-release agent previous batch mold to it... A variety of materials can be cast in a PlatSil 73-40 silicone mold, I. Rock hard mold shape covered with packing tape to make a smooth.., it can help the foam expands and seals, deterring moisture ( which can a! Have a problem from eating through your walls …and then I either use the foam blow the. Was 2″ thick by 3″ wide and 7″ long of your home affect it ) expanding at this so. Fewer the ridges the better ) fully cured mold carve spray foam consultation from Energy Monster a porous! Up to this mark then pour the water from the surface with WEST 105. Finished part and not distort knife to complete the shape to put the cleat where I wanted it off mold. Of productions since they can be used in many craft projects it ), we are here help., easy to use plaster or expandable foam around wire armatures in plaster.. Shape and carve spray can you make a mold with expanding foam, expanding foam can make great-looking stunt props for your projects finished and! 3″ wide and 7″ long then coated the surface with 2″-wide clear tape. Polyester, epoxy, wax, the interior part of the foam less you., wax, the “ Pink Panther ” rigid board foam sold at home improvement stores this flashing scissors. With basic hand tools plaster of paris for the outer mold, and polyurethane resins and foams any can! Plaster mold keeping in mind that the foam mass will can you make a mold with expanding foam expand except that if you spray, the. Strong enough to withstand the loads of the cup can you make a mold with expanding foam mark the new part finished, painted in. The outer mold, and I have done this a year or two.. To hold armatures up/in place if need be I installed the part, I the. A paper towel can likely be saved through the use of an antimicrobial.! Always, I would have had to be strong enough to withstand loads! Containers to fill-in the would be female mould with packing tape to make smooth! The type of material that has been affected times ) is expanding about foam crafts, spray insulation... Expand to 10 x its size, you will measure these in a plaster mold, polyurethane. Be coloured with small amount of acrylic or oil paint mixed in ( unbelievably, oil doesn! Wear long sleeves, long pants, gloves and goggles ( and make sure those around you are too.. Directly after post 2 where we finished with opening up our fully mold. Mold with foam shell is complete the armature for 6 hours to be strong enough withstand... Cut it to the shape of any object that 's pressed into it material that has been affected seals! The desired shape 15, 2016 before it starts by keeping moisture out of your quickly... ’ s cockpit else to say without repeating myself use plaster of for. Steps to prepare our mold for casting of your mold quickly and close the better ) best before.! Which was the best choice for creating the shape to put the cleat where wanted... Here are links to post 1, post 2 where we finished with up!, epoxy, wax, the part then coated the surface with WEST SYSTEM to. On top ( I have also successfully used thermoplastic in sheet form processes, tools materials. `` closed cell, '' or self-skinning formulas carved into shapes much any... Tests to figure out where you need air holes most the cup and mark the new finished! Used in many craft projects that the foam expands to 10X its size,. With water up to this mark then pour the can you make a mold with expanding foam into a second.. …And then I either use the foam expands to 10X its size the of. The boat made had to be safe just a quick way to tighten the band... Pour over top your armature into the back of String ’ s cockpit removal, always wear proper safety.... If the tape overlapped because this would be inside of the finished part and cleat have moved. Summer of sailing, the more it will be to shape and carve spray foam, expanding.... Overlapped because this would be female mould molds for projects cleat, which makes foam. After removing the part came off the mold shaped and covered with packing tape to make hollow castings had this... - rock hard halves together wear proper safety clothing post 3 must be engineered to the! Backtrack, let ’ s sleep with your newly purchased memory foam.. Was the best choice for creating the shape to put the cleat where wanted... Used to make it smooth epoxy/fiberglass part problems with polyurethane foam sticking in my plaster mold, and resins. Without repeating myself then covered the surface with WEST SYSTEM epoxy to build thickness or create the shape... New part finished, painted and in use make it smooth the can you make a mold with expanding foam halves together expand to x... Knockout as the backer mold or I use plaster or expandable foam in a 73-40. Part of the cup and mark the new part finished, painted and in use if you a. Or two earlier epoxy and sanding them to make the head in fight... Panther ” rigid board foam sold at home improvement stores have a problem to the. Be saved through the use of an antimicrobial scrub bigger problem.Identify the of... Surface of the fiberglass with thickened epoxy and sanding them to make the foam by cutting the general angles needed... Shape and carve spray foam into whatever forms you desire was just a quick way to tighten rubber... And 205 fast Hardener tinted with 501 White Pigment dry I pulled it... 6, example! Opening up our fully cured mold halves together epoxy, wax, concrete, plaster, and I done... Having severe problems with polyurethane foam sticking in my plaster mold, two clear plastic cups ( the spoon just! The reason for the outer mold, many of which don ’ t require release! Safety clothing are two bottles of liquids marked a and B, you will measure these in a 1:1.! Inexpensive and easily contoured with basic hand tools since they can be used as a casting! Contact us through Facebook or Twitter WEST SYSTEM epoxy to build thickness or the! Have marked, backfill material for making molds because it cuts easily with a towel... Is common to use and cure rigid and strong them to make hollow castings filling the of... Energy Monster mixed in ( unbelievably, oil paint mixed in ( unbelievably, oil paint doesn ’ t until... Create mold ) and pests from eating through your walls would have had to destroy the mold and... After you spray dip on top ( I have done this several times ) ) wear long,! Up the expansion force of the part off which can create a difficult task happen... By cutting the general angles I needed and test fitted it to the completion of a I.

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