Molding and Casting

Group assignment

• Review the safety data sheets for each of your molding and casting materials
• Make and compare test casts with each of them

Materials used:

Silicone

PIFITO Oatmeal Melt and Pour soap base 

Resin

dry putty

Silicone

Material name: Silicone

Picture:

Safety:

   -  Keep the container closed when not in use.

• Store it in a cool place.
• Keep it away from heat and flame.

• keep it out of reach of children.

Process steps:

• Mix both parts evenly according to the proportion
• Pour the mix in vacuum, it can be poured into a mold to be heated and vulcanized
• Let it operate from 30-40 minutes ,and cure from 3-12 hours ( the curing time is determined according to the curing temperature )

Mix ratio (if applicable):

• A:B = 1:1

Cured material state:

Silicone rubber is a highly adhesive gel or liquid. To convert it to silicone rubber is a highly adhesive gel or liquid. To convert it to a solid, it must be cured, vulcanized, or catalyzed. This is normally carried out in a two-stage process at the point of manufacture into the desired shape, and then in a prolonged post-cure process. It can also be injection molded. Silicone rubber may be cured by a platinum-catalyzed cure system, a condensation cure system, a peroxide cure system, or an oxime cure system. For the platinum-catalyzed cure system, the curing process can be accelerated by adding heat or pressure

Information Link

https://www.sciencedirect.com/topics/engineering/silicone-rubber 

Process pictures and comments:

1. Pouring the material of each (A and B) in cups.

2. To make sure the proportion is even, we measured the quantity of both separately, then poured them in one cup.

3. We mixed the mixture well,Then poured it into the geometric shape mold.

Result pictures:

PIFITO Oatmeal Melt and Pour soap base

Name: PIFITO Oatmeal Melt and Pour soap base

Picture:

Safety:

Soap bases start to melt around 50 to 60 C. Use heat-safe tools and handle with care – melted soap can hurt if dripped or splashed on skin.

Process steps:

1. Cut and Weigh the Melt and Pour Soap Base. Place the glass measuring cup on the scale and zero out the weight.
2. Melt the Soap Base in the Microwave.
3. Add Fragrance or Essential Oil.
4. Add Color.
5. Stir the Melted Soap.
6. Pour the Melted, Colored, Fragranced Soap Into the Mold.
7. Unmold the Soap.

Mix ratio (if applicable): 0.4-ounces of fragrance per pound of soap.

Plain lavender essential oil at about 0.4-ounce per pound.

Cured material state: When the soap is completely hardened, you should be able to pop the bars out of the mold. Some molds release easily but others may be more difficult. Tapping the mold firmly with the palm of your hand or a large spoon sometimes helps.

For a persistent bar, you can turn the mold over and run hot water over the back of it. The soap should fall easily out of the mold.

You can rub off or trim off any imperfections with a cloth or small knife.

Since the melt and pour soap base is already cured, there's no waiting. You can use your soap right away.

Information Links:

• https://aussiesoapsupplies.com.au/oatmeal-melt-and-pour-soap-kit-tutorial/
• https://www.thesprucecrafts.com/how-to-make-melt-and-pour-soap-517100

Process pictures and comments:

First of all, we cut the Melt and Pour Soap Base into small pieces and weight them.

Then, We put it into the microwave and waited for 10 seconds, 10 seconds should be enough for soap to melt.

Finally, We poured the melted soap into the mold.

Result pictures:

Resin

Name: Resin

Picture:

Safety:

1. Keep away from children.
2. Should be stored in a dry place and preferably in the original container (temperature between 20C-25C)
3. Do not swallow, call a doctor immediately if you swallowed the product.
4. Wear gloves when you use the product and wear masks for pregnants (it may cause an allergic skin reaction).
5. In case the product comes in contact with eyes, rinse cautiously with water for several minutes.

Process steps:

1. Creating the Preform.
2. Preform Layup.
3. Closing Mold.
4. Injection Phase.
5. Curing Phase.

Mix ratio (if applicable):

10 epoxy resin:6 epoxy hardener

Cured material state:

The epoxy passes from the liquid state, through a gel state, before it reaches a solid state

Information Link:

1. https://www.osborneindustries.com/news/resin-transfer-molding-process-works/
2. https://www.craft-resin.com/blogs/news/curing-hardening-craft-resin

Process pictures and comments:

First: Mix the hardener and the resin with a ratio of approximately 2 resin : 1 hardener (for example: 10 grams of resin with 6 grams of hardener)

Second: Mix the mixture for 3 minutes

Third: Pour the mixture into the mold and let it rest for 24 hours

Result pictures:

(We have added colors after pouring the mixture)

dry putty

Name: dry putty

Picture:

Safety:

Gloves and protective eyewear are recommended when using the product.

Splashes on the skin or eyes should be cleaned with clean water, and if the irritation lasts for a long time, seek medical attention.

Process steps:

• Remove dirt from holes & cracks.
• Clean the walls.
• Mix putty with water in right ratio.
• Apply the first coat of putty.
• Avoid overcoating.
• Apply a coat of primer.
• Smoothen after wall is dry

Mix ratio (if applicable):two parts white cement putty and one part water (2:1)

Cured material state:

The epoxy resin and hardener mixture has cured from solid to liquid to a final state solid, and you can dry sand it.

Information Link:

• https://www.nerolac.com/blog/precautions-to-take-for-applying-wall-putty
• https://jacanswers.com/how-long-for-epoxy-putty-to-cure/ 

Process pictures and comments:

First try

1- We measured the amount of the dry putty and water by considering the mixing ratio of 2:1. Our first try was using 18 dry putty to 9 of water.

2– Next, start mixing the mixture for a few seconds until it becomes homogeneous. Then, fill the mold and wait for 24 hours to see the final result.

Second try

We followed the directions for use that are available behind the dry putty bag.

1- We measured the amount of the dry putty and water by considering the mixing ratio of 2:1. Our first try was using 20 dry putty to 10 of water.

2- Start mixing the mixture for a minute. Then, allow the mixture to cure for five minutes. After that, again mix it thoroughly.  

3- After being done from mixing, fill the mold and wait for 24 hours to see the final result.

Result pictures:

• The final result was actually fabulous, the second try was much better than the first one due to following the instructions that were included behind the bag of the dry putty. The first try has an  issue which is fragile due to error in the mixing ratio.