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Mold Material

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Everide
Posted: Sun Jul 16, 2006 1:35 pm Reply with quote
Joined: 16 Apr 2006 Posts: 81 Location: MidWest
Just wanted to know if anybody has any suggestions on what to use to make the molds for my press.

I'm thinking either concrete or a resin of some sort. Any other ideas?

Here is a drawing of what the press will look like:

http://img45.imageshack.us/img45/1414/ddcr1.jpg
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CH3NO2JAY
Posted: Mon Jul 17, 2006 4:15 pm Reply with quote
Joined: 13 Jan 2002 Posts: 7303 Location: Chicago
Link doesn't work for me.

Probably the cheapest way to go is Cement.
I still wonder what a big Urethane or Alloy mold would cost via a CNC machine instead of concrete.
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Lincolnz
Posted: Mon Jul 17, 2006 4:45 pm Reply with quote
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Joined: 05 Jun 2005 Posts: 11215
CH3NO2JAY wrote:
Link doesn't work for me.

Probably the cheapest way to go is Cement.
I still wonder what a big Urethane or Alloy mold would cost via a CNC machine instead of concrete.


Getting one milled out of alloy would be pricey.

I wonder how delerine(sp) would work or if it would be too soft.

Or making one out of a solid block of hardwood.

We my brother makes his mold for the yahts he builds he makes them out of fiberglass and does a vaccum method. I don't imagine it would hold up to a hydro press.

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Everide
Posted: Mon Jul 17, 2006 5:24 pm Reply with quote
Joined: 16 Apr 2006 Posts: 81 Location: MidWest
I know cement is the cheapest way. You can reinforce it with rebar and that fiber they put in. I talked to a guy about it and he suggested 60 carbon rebar every 4 inches, several layers, and adding the fiber. I forgot what the bag count was though.

I also looked into melting aluminum. Seems like it would work nicely if you are ambitous:

http://www.backyardmetalcasting.com/

It would be a little more work, but would last really long. I figured about 4-7 gallons of molten aluminum for one half of a mold. You'd just need to drink a lot of beer

I'll probably do it with cement until I can upgrade.
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pennswood
Posted: Mon Jul 17, 2006 5:26 pm Reply with quote
Joined: 14 Sep 2003 Posts: 213
we have used everything.

cement is the cheaper way to go.
but it takes up to 30 days to have enough cure.
also it is under much pressure, and has a tendency to explode.
there are some additives you can put in to help.

next is wood,
a solid wood or laminated block,
slices of the concave shape are vertically laminated,
then sanded into shape.
high level of craftsmanship and tools.

then we have a poured urethane product.
the cost if you dont fuck it up is about $ 300 per mold set.
this product is a 2 part liquid
when mixed together then poured into a mold form,
it hardens to amazing levels in about 2 hours.
this will require a mold form for the pour,
and a high level of skill to build the form.

then we move into cnc molds,
requires a 3-d cnc mill,
with a very complex cutting program,
each side of our mold, top and bottom,
are cut to perfect tolerances,
from a huge piece of aluminum that cost about $ 2000,
it took 20 hours of cnc time to cut each half.
then i paid to have a board laser scanned,
from one of our previous handmade molds.
then we threw some geometry on it with a 3-d CAD.
i had to pay the cad guys another $2000 for the programming.
we paid to have 5 mold sets done, and it was not cheap.

so what i have come to now is we just duplicate the exsisting
cnc cut molds with the urethane method.

i should have not cut all our initial 5 molds from aluminum.
just made 1 set for perfect mold forms.
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Dan
Posted: Tue Jul 18, 2006 7:07 am Reply with quote
Joined: 11 May 2005 Posts: 45 Location: USA
Overflowing with metal(aluminium or else ) is not recomended couse metal when cools has trends,tendence to shrink near 1/3 inches,any polishing not gave result.
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Lincolnz
Posted: Tue Jul 18, 2006 8:31 pm Reply with quote
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Joined: 05 Jun 2005 Posts: 11215
pennswood wrote:

then we move into cnc molds,
requires a 3-d cnc mill,
with a very complex cutting program,
each side of our mold, top and bottom,
are cut to perfect tolerances,
from a huge piece of aluminum that cost about $ 2000,
it took 20 hours of cnc time to cut each half.
then i paid to have a board laser scanned,
from one of our previous handmade molds.
then we threw some geometry on it with a 3-d CAD.
i had to pay the cad guys another $2000 for the programming.
we paid to have 5 mold sets done, and it was not cheap.

so what i have come to now is we just duplicate the exsisting
cnc cut molds with the urethane method.


Yeah I use to work in a machine shop making molds. The shit ain't cheap at all.

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devotid
Posted: Thu Aug 10, 2006 11:03 pm Reply with quote
Joined: 20 Apr 2006 Posts: 26 Location: saginaw, MI
Ive made three cement molds with rebar in them and use them for pretty high production making wakeskates. works great. the two part epoxy system is exspensive and i made a mess trying it with some stuff from a guy at QCM technologies. google it and ask for roy. hes as cool as a fan.
just didnt work for what im doing.

my 2 cents
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Everide
Posted: Sat Aug 12, 2006 8:47 pm Reply with quote
Joined: 16 Apr 2006 Posts: 81 Location: MidWest
Yeah, I chose the cement route. I made it a three cavity press. Popped the first board out yesterday

The cement seemed to hold out pretty well. I made each mold 28" thick (top and bottom combined) put two vertical and two cross layers of rebar and added fibermesh. seemed to work out ok.

Only problem I had was when my molds were open my cylinder didn't fit. I'll have to revamp the press a bit.

If I get a chance I'll post a pic or two.
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fishbowlproject
Posted: Sun Aug 20, 2006 9:24 pm Reply with quote
Joined: 10 Aug 2006 Posts: 62
Everide, Did you have more sucess troweling the concave or making a pre-form from another material? Thanks
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