Bill Mellberg & Greg Ketell
Bay Area Woodturners Association
Introduction to Casting
!
!
!
!
!
There are many materials that are called resin for
art and craft casting applications.
Specifically clear or water clear liquid resins are
used for casting and encapsulating objects.
Laminating resins are used with fiber
reinforcements and should not be used to cast.
There are many U-Tube and web based
instructions on casting resins for the hobbyist.
Safety is paramount when handling liquid resin
components or solvents. Always use Personal
Protection Equipment (PPE) for hands, eyes,
breathing.
Safety First
!
!
!
!
Maintain adequate ventilation in
the shop
Use Nitrile gloves to protect you
hands
Use acetone to clean tools and
surface spills
Protect work surfaces with poly
sheeting
!
!
!
Wear safety glasses, goggles or
face shield
Wear a shop apron or smock over
your cloths
Use a organic vapor respirator to
protect your lungs when
measuring or mixing.
Material Science 101
!
Plastics come in two types
" Thermoplastic vs. Thermoset
One softens with the application of heat the other is
unaffected by heat other than post cure properties.
" Liquid resin systems are Thermosets
They transition from liquid to solid by way of polymer
reactions called crosslinking forming molecular chains
that are strong and stiff. Higher crosslinking = harder
polymer
These resin systems consist of two components (A/B)
" Resin (A) and Hardener (B) are precisely weighed or
measured by volume, then thoroughly mixed to distribute the
resin components for optimum cure.
Resin Comparison
Resin
Type
Polyester
Casting
Resin
Urethane
Working
Time
15-30
minutes
5-10
minutes
Cure
Time
24 hours
45-90
minutes
Viscosity
Thin
Medium
Smell
horrible
None
Cost
/Qt
Best used for
Sample
$32
Stabilizing,
small void filling
USComposites
Silmar 41
$40
Multi-color
Blanks, large
void filling
Alumilite
Water Clear
Materials Science 101
!
!
Water Clear Liquid Casting Resins
Compounds called Reaction polymers polyfunctionals
" Epoxy
Hardeners include amines & acid anhydrides, may require heat to cure
Requires accurate measurements of both components (A/B)
Usually not optically clear, amber in color, poor UV resistance
" Polyester
Styrene is used to lower the viscosity
Crosslinking is initiated by adding organic peroxide
" Benzoyl peroxide or MEK Peroxide
Obnoxious odor, requires good shop ventilation
" Polyurethane
Isocyanates react with water forming urea & CO2
Metal complex catalysts are based on Mercury, use PPE for safety
Low moisture fillers required. Limited shelf life, poor long term storage.
Fast cure times, removal of air is a problem. Pressure cast equipment
needed.
Types or Styles of Castings
Richard Greenwald Names
!
!
!
!
!
!
Swirl: Intertwine 2 or more resin colors (marble)
Splotch: Drop gelled resin blobs into base color
Crackle: Broken chunks of resin in colored base
Left Overs: Same as Crackle above in clear base
Vein: Insert colored lines of resin prior to gel
Ribbon: Continuous length of gelled resin or colored plastic sheet,
looped into mold prior to color pour
Shop Support Tools
!
!
!
!
!
Gram scale for weighing
components
Bottles with sealable caps or
dispensing tips
Color pigments in powder or liquid
Clean molds without cracks or cuts
Disposable mixing cups
" unwaxed paper or PETE (#1) plastic
Tongue depressors or wooden stir
sticks
! Measuring cups or graduated
beakers
! Shop or paper towels for clean-ups
! Old Newspapers for secondary
table top protection from spills
!
Types of Casting Molds
!
!
Store bought, size specific, polyethylene
Old household containers, retired from
use!
" Tupperware, Rubbermaid, Ziploc,
laundry caps
Cast Silicone, size specific, pen blank
(flexible)
" Store bought or self cast from
components
!
!
!
Formica clad wood or metal clad wood
" Must use release agent on surface
PVC pipe
HDPE/UHMW Plastic (cutting boards)
Casting How To
General
!
!
!
Organize you work space with resin, molds, mold release, colorants,
mixing cups, etc
Select your colors and insure they are moisture free
Keep a note book of your measurements, color combinations, and
pouring-order so you can replicate your creations
Casting How To
Polyurethane
!
!
Measure each part by weight per instructions
Mix colors with part B.
" When you like the look, double all your amounts.
!
!
!
Stir slowly to prevent bubbles
Combine both parts A / B stirring slowly
Pour mixture slowly into your prepared molds
" Strategically mix colors to create interesting designs
!
!
!
!
Place molds inside Pressure Pot and apply 60 psi
Release pressure after 30 minutes
Allow to cure at least an hour before de-molding
Cut slab into square lengths to match pen tube
Casting How To
Polyester
!
!
!
!
!
!
!
!
!
!
Measure resin by volume
Mix colors with base resin. Stir slowly to prevent bubbles
Add activator (MEKP) at 4-10 drops per ounce of resin
Mix thoroughly
Pour mixture slowly into your prepared molds
Strategically mix colors to create interesting design
Place molds inside Vacuum Pot for about an hour
Optionally, place molds in a Pressure Pot and apply 60 psi
Allow to cure overnight before removing from Pressure Pot
and de-molding
Cut slab into square lengths to match pen tube lengths
Making your own blanks
! Matching
dress
a customers bridesmaids
Making your own blanks
! Favorite
Colors
Making your own blanks
! Utilizing
pretty wood scraps
Making your own blanks
! Getting
Creative
Sources of Supplies
!
Casting Molds
" PETE: TAP Plastics, Douglas & Sturgess
" Silicone: CraftSupplies, IAP-vendors
" Home Made
Resin
" Urethane:
Alumilite (Clear, NOT Water Clear) from Alumilite
Smooth-On (Crystal Clear 202) from Douglas & Sturgess
" Polyester Resin (PR):
(Silmar 41) from USComposites,
(Apprentice Casting Kit) from CraftSupplies
Colorants
" PearlEx: Michaels
" Luster Pigments: Douglas & Sturgess
" Dyes: Alumilite, TAP plastic
Mixing cups
" Safeway, Starbucks, Smart & Final
Stir Sticks
" Michaels
