Making Parts, Patterns, Tools, & Molds
Making tools and molds, and casting parts and patterns is
an art many centuries old, made easier and more accessible
by many recent advancements in materials, especially
urethanes, epoxies, waxes, and silicone rubber.
This series of videos started out as merely a complement to
Freeman’s industry-leading technical support. But it has
since grown to become one of the most comprehensive
resources on moldmaking, casting and laminating, for both
novice and experienced toolmakers alike.
We start off with the
fundamentals,
beginning with a brief video introducing the most
popular process for creating models--going from
imagination to
computer-aided-design software to CNC milling
machines.
From here, we demonstrate the
proper procedures for sealing and releasing
your models and molds,
which is critical in order to prevent your creations
from sticking to each other. Next, we demonstrate how to
calculate your material requirements and the
proper procedures for weighing and mixing
materials.
Finally, we have a separate segment on benefits
of
vacuum degassing and pressurizing
certain materials for producing defect-free castings.
The next section demonstrates various mass casting
processes, which are most commonly used in the construction
of smaller molds and parts, usually less than 12 inches
square.
First, we demonstrate the construction of three simple
molds; one made from a rigid fast-cast urethane, one from a
flexible urethane rubber, and one from a flexible silicone
rubber, each with its own unique set of advantages and
disadvantages. Then we move onto more complex molds, such
as two part molds using opaque silicone rubber, and
two-part molds using clear silicone rubber. Next, we’ll
show the unique challenges of casting multiple-part molds
and casting thin-walled parts. Finally, we complete this
section with a demonstration of surface casting.
The next section deals with laminating, which includes
several process used primarily in the construction of
larger molds. We begin with the basics of using surface
coats, laminating resins, and fiberglass cloth. Then we
demonstrate the Paste Laminating process and then the Repro
Surface Coat and Laminating Resin System, both most
commonly used in the construction of medium-sized molds.
Lastly, we take you through the process of creating a glove
mold, which is a unique two part mold with a rigid layer
and a flexible layer of material.
Following this section is a brief overview of many of the
products available from Freeman Manufacturing & Supply
Co. In this section we also go further in depth over
differences in technology, different applications for many
materials, and some of the pitfalls inherent in various
chemistries that every toolmaker should be aware of, giving
you a greater sense of the wide variety of materials
available to the modern artisan and toolmaker and helping
you narrow down your choices to choose the best materials
for each project.