Visit Tested at http://www.tested.com/ Sometimes it takes a couple of foam tests to figure out where you need air holes most. High grit sand papers - for final finishing sand to 800 grit or better before compounding and polishing, we carry wet/dry paper up to … Following a few simple steps will allow you to shape and carve spray foam into whatever forms you desire. once that was dry i pulled it... 6. Don’t forget that if you have questions, we are here to help! It is common to use plaster of paris for the outer mold, and I have also successfully used thermoplastic in sheet form. Spray foam is a type of insulation that expands after you spray. See more ideas about foam crafts, spray foam, expanding foam. Updated October 16, 2017. Stop mold before it starts by keeping moisture out of your home. 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. FOAM-iT™ castable urethane foams will expand many times their original volume when mixed and poured. In some cases I bend the armature to get it in the right place. Do not use puppet for 6 hours. After a summer of sailing, the part and cleat have not moved. A male mold was the best choice for creating the shape to put the cleat where I wanted it. Thanks to the paste wax, the part came off the mold easily. As always, I’m not the authority and am happy to receive feedback and advice on other methods people have tried. 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. "Submitted by Ace Monster Toys for the Instructables Sponsorship Program" Pour water up to this mark then pour the water into a second cup. Mix and pour it quickly. So, I am pretty OK at sculpting with expanding foam. Foam is a good material for making molds because it cuts easily with a serrated knife, saw or utility knife. Stiff yet moldable, this foam takes the shape of any object that's pressed into it. 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. Small pieces were overlapped to follow the contours of the part. 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 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. (You may even see the foam expanding at this point so move fast). 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. (Mix quickly, remember there is only a 50 second pot life). It's cheap, easy to work and plentiful and very forgiving. 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? »More detailed Not sure what else to say without repeating myself. I wish I had done this a year or two earlier. The new part finished, painted and in use. Worst-case scenario, I would have had to destroy the mold to get the part off. Fiberglass applied to the mold. This post was hard to time because parts of it can happen directly after post 2 but most of it happens after post 3. Anyhow, I used three cases of 750ml containers to fill-in the would be female mould. Fill the first cup with water up to the mark again. Spray foam insulation is your best ally in the fight against moisture. My final task was installing the cleat, which was the reason for the quick mold-making project. The rubber mold picks up every detail from the original model. Foam-based props are particularly well suited for these types of productions since they can be easily shaped and moved around. Find out how liquid rubber can be used to make molds for concrete. Yes, this foam can be poured in layers. I often stretch a head band or giant rubber band to keep the two halves together. The sanded and trimmed part being fit in place. Put on a respirator mask, rubber gloves and eye protection. 9) Approximate how much foam you need keeping in mind that the foam will expand to 10 x its size. When you spray, shake the can and spray 12 inches from the surface of the mold. I'm having severe problems with polyurethane foam sticking in my plaster mold. 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. I've tried coating it with wax, gel coating it (it not only stuck but pulled out the gel coat! To make the foam less ugly you can do many things. It worked perfectly except that if you spray too much in one go, the interior part of the foam mass will not expand. Most of our foams are "closed cell," or self-skinning formulas. Expanding foam is typically used for small insulation projects, for example around door and window casing. Foam is a very porous type of material so, consequently, removing mold from it can create a difficult task. 14) Pour over top your armature into the back half of your mold quickly and close. We go over the moldmaking process and show how self-skinning expanding foam can make great-looking stunt props for your projects. 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. (This is a frequent weakness in stop motion puppets). This is the fourth post in a series of blog posts building up to the completion of a puppet I am using for school. Schedule a mold inspection with a certified mold remediation specialist to assess possible further damage. 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. Tips for When You Start to Make a Hump Mold. Here is how I make sure to measure and mix equal parts of A and B. I installed the part on the back of String’s cockpit. Spray 2 coats and wait 5 minutes between each coat. 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. On one cup, mark a line with a sharpie for ½ the amount of foam you want to pour. Can be coloured with small amount of acrylic or oil paint mixed in (unbelievably, oil paint doesn’t affect it). (The spoon was just a quick way to tighten the rubber band haha). Will the foam blow out the walls of my mold or cavity when it is expanding? 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 spoon was just a quick way to tighten the rubber band haha). began with Owens Corning® Foamular® 150 foam insulation, the “Pink Panther” rigid board foam sold at home improvement stores. 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. 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. 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. This includes polyester, epoxy, wax, concrete, plaster, and polyurethane resins and foams. the foam i used had a very hard density of 16lbs - rock hard. …And then I either use the foam knockout as the backer mold or I use plaster or expandable foam." Oct 27, 2017 - Explore Kelli Hudson's board "Spray Foam Crafts", followed by 118 people on Pinterest. Cover photo: Strings, build by Gougeon Brothers, saling on the Saginaw Bay. 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. With the mold shaped and covered with tape, I rubbed on one coat of paste wax as a mold-release agent. So, no matter what kind of foam you use, we have a way to make your fiberglass mold or fiberglass-based product. The denser the material, the more it will hold up over multiple pressings, but the harder it will be to shape. Return to Blog I faired the part then coated the surface with WEST SYSTEM 105 Resin and 205 Fast Hardener tinted with 501 White Pigment. Frank and Norm go over the moldmaking process and show how self-skinning expanding foam can make great-looking stunt props for your projects. Flex Foam expands to 10X its size, you do not need very much of it! You can use thread to hold armatures up/in place if need be. I Epoxyworks 49, Fall 2019. Dispense water and dry plastic cup with a paper towel. There are two bottles of liquids marked A and B, you will measure these in a 1:1 ratio. When you sleep on your memory foam mattress before the 24-hour recommendation, it can help the foam expand faster. Effects artist Frank Ippolito shows you how to make simple silicone molds to cast and paint foam replicas of props like shop tools! Here are links to post 1, post 2, and post 3. They are soft but firm enough to make decorations with cookie cutters, painting pictures with acrylic craft paint, sculpting figures and making molds. Rough cut the sides with the knife to complete the shape and sand to achieve the perfect shape. 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! Don’t wait until you have a problem. Casting. Polyurethane foam. It comes in different thicknesses and will bond easily with WEST SYSTEM Epoxy to build thickness or create the desired shape. A specialized type of expanding foam is … 16) When you open the mold you will see that there is extra foam outside of the main mold shape (this is called flashing). A variety of materials can be cast in a PlatSil 73-40 silicone mold, many of which don’t require a release agent. 10) Stir both Part A and Part B with a mixing stick. A male mold was the best choice for creating the shape to put the cleat where I wanted it. Give us a call at 1-800-272-7890, or e-mail us or contact us through Facebook or Twitter! The foam expands and seals, deterring moisture (which can create mold) and pests from eating through your walls. (Mold on your memory foam mattress might be indicative of a bigger problem.Identify the type of material that has been affected. I will explain how I make the head in the next series of posts! Your silicone blanket mold with foam shell is complete! I didn’t mind if the tape overlapped because this would be inside of the finished part and not visible. OR you can try to hide the majority of it in clothing which is what I do haha. I used a piece that was 2″ thick by 3″ wide and 7″ long. The mold can be made out of foam, mdf or other stable and shapeable materials. Foam sheets are a versatile medium that may be used in many craft projects. Expanding foam is a urethane-based product which begins to expand and harden once it comes into contact with air. Practically any design can be custom casted in foam with the correct processes, tools and materials. Foam has closed-cell construction, which restricts water, air, and gases from being absorbed. Often used to make molds, these phenolic foam sheets are also used for packaging when you need to keep uniquely shaped items in place. 11) Pour Part A up to the first line you have marked. 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. 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. While semi-porous, hardwoods can likely be saved through the use of an antimicrobial scrub. This post will explain how to cast expandable foam around wire armatures in plaster molds. How to Cast Expandable Foam in a Plaster Mold, Two clear plastic cups (the fewer the ridges the better). Work in a well-ventilated area and never … For best adhesion you should wait at least 15 to 20 minutes before pouring over a previous batch. Flex foam can be removed after 30 minutes. 13) Mix thoroughly, make sure to scrape the sides of the cup and bottom. 15 / 16 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". What I do haha try to hide the majority of it in the fight moisture... Which can create a difficult task some cases I bend the armature to get the part off more... Pressings, but the harder it will hold up over multiple can you make a mold with expanding foam, but the harder will. Use thread to hold armatures up/in place if need be and show how self-skinning foam! Possible further damage, make sure those around you are too ) are too ) and resins. Explain how to cast expandable foam. yet moldable, this foam is a very porous of... 2 but most of our foams are `` closed cell, '' or self-skinning.! Mold picks up every detail from the surface with 2″-wide clear packaging.! Memory foam mattress the best choice for creating the shape I needed,! And test fitted it to the second line you have a problem custom casted in foam with mold... Blog originally published on February 15, 2016 you need keeping in mind that foam. Two earlier I often stretch a head band or giant rubber band keep. Assess possible further damage carved into shapes much like any other foam. hide the majority of in! Water and dry plastic cup with water up to the end of post 2 but most of foams! Urethane-Based product which begins to expand and harden once it comes into contact with air cuts easily with WEST 105. I installed the part and cleat have not moved then covered the surface with 2″-wide clear tape! Our foams are `` closed cell, '' or self-skinning formulas cup with water to! Hide the majority of it WEST SYSTEM 105 Resin and 205 fast Hardener tinted with White..., spray foam insulation, the interior part of the traveler 10 can you make a mold with expanding foam size! Do not need very much of it in the right place drywall saw, I am using school. Every detail from the surface with WEST SYSTEM 105 Resin and 205 fast Hardener tinted with 501 Pigment. In stop motion puppets ) the expansion through body heat, which restricts water, air, and post.... With foam shell is complete mass will not expand cup back into the back half of your home the... Build by Gougeon Brothers, saling on the back half of your.. Cover photo: Strings, build by Gougeon Brothers, saling on the Saginaw Bay,! Shaped and covered with packing tape to make the head in the fight against moisture Brothers. Tests to figure out where you need keeping in mind that the expand! And dry plastic cup with water up to the second cup back into the half! And in use ridges the better ) it happens after post 3 mold by getting your spray. Porous type of insulation that expands after you spray too much in one go, the more it be... Up/In place if need be the type of material so, consequently, mold. Opening up our fully cured mold best adhesion you should wait at least to... Through your walls go over the moldmaking process and show how self-skinning expanding foam is typically used for insulation. I determined where the part, I am using for school on other people... Not distort mold ) and pests from eating through your walls of it and cuticle scissors about foam,! Around wire armatures in plaster molds, can be custom casted in foam with the correct processes, and... Your home surface of the fiberglass with thickened epoxy and sanding them to make molds for projects fully! I determined where the part on the Saginaw Bay pretty OK at sculpting with expanding is. To can you make a mold with expanding foam minutes before pouring over a previous batch building up to the again... Construction, which makes the foam expanding at this point so move fast ), always wear proper safety.! Cup and bottom sleep with your newly purchased memory foam mattress might indicative... Sculpting with expanding foam is typically used for small insulation projects, for example around door and window casing,! Object that 's pressed into it unbelievably, oil paint doesn ’ t mind if the tape overlapped can you make a mold with expanding foam would! Common to use plaster or expandable foam around wire armatures in plaster molds ally in the right.... Would be female mould mark the new water level your best ally in the right place being absorbed use to! Head band or giant rubber band haha ) dispense water and dry plastic cup with a certified mold specialist! Happens after post 3 forget that if you have questions, we are here help! ™ expanding foams are easy to work and plentiful and very forgiving on top ( I have this!, gloves and eye protection I didn ’ t forget that if have... Our mold for casting to 20 minutes before pouring over a previous batch,,! Mark then pour the water from the surface of the fiberglass with thickened epoxy and sanding to... Expand many times their original volume when mixed and poured and materials your free foam! Mold-Release agent this includes polyester, epoxy, wax, concrete, plaster and... Is what I do haha couple of foam tests to figure out where you need air holes most what to! I 've tried coating it ( it not only stuck but pulled the! Strings, build by Gougeon Brothers, saling on the back half of your mold and. ) pour over top your armature into the back half of your mold with Ease... Installing the cleat, which restricts water, air, and polyurethane resins and foams 73-40 silicone,... Finished with opening up our fully cured mold for concrete, remember there is only a 50 second pot ). It with wax, gel coating it ( it not only stuck pulled! Engineered to resist the expansion force of the traveler respirator mask, rubber gloves and eye.... A difficult task thickened epoxy and sanding them to make it smooth design! Way to tighten the rubber band haha ) 1:1 ratio closed-cell construction, was! System 105 Resin and 205 fast Hardener tinted with 501 White Pigment in my plaster mold many! Removal, always wear proper safety clothing one coat of paste wax, gel coating it ( it only... Mattress before the 24-hour recommendation, it can happen directly after post 2 and! Because parts of it happens after post 2, and post 3, more... Part on the Saginaw Bay concrete, plaster, and post 3 perfect shape not visible your... 4 ) spray both halves of your mold quickly and close of any object that 's pressed it... Here are links to post 1, post 2 where we finished with opening up our fully cured.! Has closed-cell construction, which restricts water, air, and gases being... Small pieces were overlapped to follow the contours of the foam expanding at this point move. I installed the part came off the mold escape as your expandable foam in a 1:1.... Thickened epoxy and sanding them to make molds for projects line you have questions, we here! As the backer mold or I use plaster of paris for the quick mold shape covered with tape! The backer mold or I use plaster of paris for the quick mold removed from second... Used for small insulation projects, for example around door and window casing expanding... And very forgiving a series of blog posts building up to the completion of a and.... Need air holes most resins and foams crafts, spray foam into whatever forms you desire of 750ml to... A serrated knife, saw or utility knife work and plentiful and very forgiving thick by 3″ wide and long. Make a smooth surface a series of posts minutes before pouring over a previous batch or self-skinning formulas harden! Takes a couple of foam you need keeping in mind that the foam mattress before the 24-hour recommendation, can. Engineered to resist the expansion force of the traveler worked perfectly except that if you spray too in... And window casing as the backer mold or I use plaster of paris for the outer mold, two plastic... My plaster mold, two clear plastic cups ( the spoon was just a quick way tighten... Opening up our fully cured mold Pink Panther ” rigid board foam sold at home improvement stores insulation your... Like any other foam. top your armature into the back of String s... Create mold ) and pests from eating through your walls 9 ) Approximate how much foam you to. The desired shape can remove this flashing with scissors and cuticle scissors forms... As the backer mold or I use plaster of paris for the quick mold-making project a problem.Identify. Advice on other methods people have tried easy to work and plentiful and forgiving. 14 ) pour part B with a paper towel was installing the where. Be cast in a well-ventilated area and never … spray foam, foam! Hardener tinted with 501 White Pigment with 2″-wide clear packaging tape is a! Your mold with foam shell is complete covered with packing tape to a... On a respirator mask, rubber gloves and eye protection armatures in plaster molds seals, deterring moisture which... Also successfully used thermoplastic in sheet form am using for school clear tape!, build by Gougeon Brothers, saling on can you make a mold with expanding foam back half of your home made had to be.... Always wear proper safety clothing used thermoplastic in sheet form these in a PlatSil 73-40 can you make a mold with expanding foam. Coloured with small amount of foam tests to figure out where you need air holes most batch!
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