Manual & Catalog

MOLD MAKING & CASTING

Discover the Flexibility of

Liquid Mold Rubbers and Casting Plastics

10th Edition
Advancing the State-of-the-Art in Art & Industry
TM

WELCOME!
Welcome to the 10th Edition of Polytek Development Corp.s MOLD MAKING & CASTING MANUAL & CATALOG. We wrote this manual to help you use the many products and materials Polytek offers to their maximum benefit. Mold making and casting are not easy. In fact, making molds and castings is a full-time career for many skilled craftsmen. An important part of a master mold maker's expertise is developing a feel for the way each different molding and casting material behaves. Developing this feel for each material and learning to anticipate and avoid common problems takes a great deal of practice with a variety of materials. Consequently, it is difficult for anyone to try a new technique or use a new material the first time and achieve perfect results. Thus, the old adage, "Practice makes perfect." Polytek has formulated a range of materials to help you achieve your molding and casting objectives, and we are constantly working to invent new products to make your job easier. As good as any material may be, however, the skill of the user is equally important in achieving the objective. When you use a material for the first time, we ask that you start small and simple to get a feel for the material before going on to larger projects. Our goal is to continue to produce dependable, quality materials and present their basic methods of use. The rest is up to you. We depend on your success and want to help whenever possible. Thank you for your patronage. Sincerely, Bob LeCompte Chairman

CUSTOMER SERVICE

When you call Polytek, you can speak to a member of our customer service team (Joe, Stan, Wendy, Dave, Laurie, Jill, Mary, Larry and Bill). They all have hands-on experience and the knowledge and ability to satisfy your needs quickly. Whether youre new to mold making and need help getting started or an expert mold maker looking for a fresh perspective, we welcome your questions. We know that our continued success is based on the quality of our products and service and the word of mouth of satisfied customers.

MOLD RUBBERS & CASTING PLASTICS

Polytek offers the most complete line of mold making and casting materials available anywhere. For mold making, Polytek produces polyurethane and silicone liquid rubbers in many hardnesses as well as latex, alginate and wax. For casting, Polytek manufactures rigid and flexible polyurethane plastics and foams and castable epoxies. Polytek is a one-stop source for mold making needs: we offer a full line of accessories including release agents, training DVDs, scales and more. If we dont have what you need, call us -- we can develop custom formulas within weeks.

POLYTEKS LOCATION

SEMINAR & WORKSHOP

Polytek offers a popular, two-day seminar and workshop titled Mold Making and Casting Methods and Materials. The first day begins with a comprehensive presentation and demonstration of mold making techniques and materials. Later in the day the workshop portion gets started. Attendees are encouraged to bring a small, simple model. Polyteks expert technicians review each model and discuss mold making options with the group. Then each attendee gets hands-on experience using Polyteks products to make a mold and casting of their model. Enrollment is limited to 20, meaning that each attendee gets plenty of one-on-one guidance from Polyteks staff. The seminars are conducted in Polyteks well-equipped, 5,000-ft2 mold making and casting shop in Easton, PA. The cost is $400 for the seminar and workshop (includes materials) or $200 for the first day only (with no handson use of materials). Call for seminar dates. Enroll early! Seminars fill fast!

Our state-of-the-art facility is located at 55 Hilton Street, Easton, PA -- just off I-78, Exit 75. You can see us from the highway! Stop in! We use our 5,000-ft2 mezzanine for product demonstrations, trials, and seminars. Take time to enjoy nearby historic Delaware River inns and attractions. Were only 90 minutes to New York City and Philadelphia.

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BY PHONE (800) 858-5990 (610) 559-8620 Monday to Friday 8:30 a.m. - 5:00 p.m. BY MAIL Polytek 55 Hilton St. Easton, PA 18042 ONLINE sales@polytek.com www.polytek.com Secure credit card transactions BY FAX (610) 559-8626 24 hours a day

Specialty Molding/Casting Materials . . . . .57 Latex Rubber Products Poly Wax 15 Poly Skin-Wax Hydrogel N Mold Compound

DISCLAIMER: The information in this catalog and otherwise provided by Polytek is considered accurate. However, no warranty is expressed or implied regarding the accuracy of the data, the results to be obtained by the use thereof, or that any such use will not infringe any patent. Before using, the user shall determine the suitability of the product for the intended use and user assumes all risk and liability whatsoever in connection therewith. 2007 by Polytek Development Corp. All rights reserved. This manual may not be copied, in whole or in part, without written consent of Polytek Development Corp.

www.polytek.com

Accessories 1

Accessories . . . . . . . . . . . . . . . . . . . . . . . . .61 Pol-Ease Releases PolyFiber, Bronze and Other Fillers Safety Equipment Mixers, Scales, Books, DVDs & More

Speciality Materials

Casting Plastics

CONTACT INFORMATION

Casting Plastics/Resins . . . . . . . . . . . . . . .46 EasyFlo & Poly 15 Series Plastics Poly-Optic 14 Series Clear Casting Resins PolyFoam, LiteCast, Plasti-Flex & Polygels Epoxy Resins & Curatives

Silicone Mold Rubber

Use Polytek products creatively and enthusiastically for a variety of projects -- from creating fine art to producing functional pieces for home and industry. Mold making and casting are truly CREATIVITY WITH C HEMISTRY . The use of Polytek materials is limited only by the imagination -- may yours be limitless.

Silicone RTV Mold Rubbers . . . . . . . . . . . .40 TinSil 70 Series Silicone Rubbers PlatSil 71 Series Silicone Rubbers PlatSil 73 Series Silicone Rubbers PlatSil Gel 10 Silicone Rubber

Polyurethane Mold Rubber

The remarkable, life-size Carrara marble sculpture by E. Zocchi of a young, enthusiastic Michelangelo carving a gargoyle depicts four of our favorite things ... art ... creativity ... enthusiasm ... and gargoyles!

1 2 3 4 5 6

Polyurethane RTV Mold Rubbers . . . . . . .32 Poly 74, Poly 75 & Poly 77 Series Rubbers Polygel Brushable/Sprayable Rubbers Poly 81-Series Rubbers Poly-Fast 72-40 & Poly GlassRub Rubbers

Mold Making Methods

CREATIVITY WITH CHEMISTRY

Mold Making Methods . . . . . . . . . . . . . . . . .2 Mold Making & Casting Materials Types of Flexible Molds & Castings Mold Making & Casting Procedures Applications

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Mold Making Methods

Mold Making Methods

GETTING STARTED
When making a flexible mold of an object in order to cast reproductions, you are faced with many choices of mold making and casting materials and methods -- it can be bewildering at first glance. In order to succeed, you must consider many factors before you start a project. Here are a few things to think about: What is the model made of? Does the shape of the model present mold making or demolding challenges? What will the casting be made of? How many castings do you envision making? How much money do you plan to spend? How much time do you have to complete the project? Think ahead. You need to plan your project from start to finish before you begin. Read the Methods sections entirely so that you understand all of the factors that need to be considered during the planning stage of your project.

To have a successful mold making experience,

PLEASE ... Study. Read as much "how-to" literature as

possible. Watch instructional DVDs and videos (see p. 63).

Start Small. Make a small, simple mold and

casting before attempting an important piece. Get a feel for the materials without costly mistakes. Experiment with small Trial Units (see p. 65).

Ask Questions. Its difficult to tell you how

to make molds and castings over the phone, but well try! Please call Polytek Customer Service with questions.

MOLD MAKING & CASTING MATERIALS

Polytek Development Corp. produces nearly all types of flexible mold materials commonly used today as well as many casting materials. Before beginning a mold making project, you must understand the advantages and disadvantages of various mold making and casting materials. At the same time, you must consider the type of mold you envision, because that too will play a factor in selecting appropriate mold making and casting materials. For information about types of flexible molds, refer to pp. 7-9. Flexible mold materials range from simple, one-part latex (the natural product of the rubber tree), Hydrogel N (alginate, a powder to which water is added), and Skin-Wax (which is melted for use), to the higher performance two-part polyurethane and silicone mold rubbers. Polyteks two-part systems consist of two liquids that after mixing together react to form rubber. These systems cure at room temperature and, therefore, are are referred to as room temperature vulcanizing (RTV).

Each mold making and casting compound is unique and may require special handling that differs from similar products. Spend time learning the special requirements of every new product and making a small test mix before using the product on a larger scale to avoid loss of valuable time and materials. Mold making and casting materials must be selected concurrently. This is because some casting resins work well only in certain mold materials (and vice versa). If you have a specific casting material in mind, then you select a mold material that works well with that casting material. Most often you can find mold and casting materials that work well together and satisfy all of of your project requirements. The illustration below helps to demonstrate this point.

Casting
Wax Concrete Plaster Epoxy

Mold Material
All (except Skin-Wax) Polyurethane All (usually polyurethane) Polyurethane or silicone Silicone or polyurethane Silicone or polyurethane Silicone or polyurethane Silicone or polyurethane

Selecting proper mold making and casting materials for the job at hand is the 1st step to success!
2

Polyurethane Polyester Acrylic Metal (low-melting)

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Mold Making Methods 3

SELECTING A MOLD MAKING MATERIAL

To select the best mold making material for your project, consider several factors: model composition, shape and size; mold type; cost; and timing. First, familiarize yourself with the common types of flexible mold making materials and the advantages and disadvantages of each. After you have learned about the various mold materials, take into account the characteristics of your model and the mold making challenges it presents. The tables below highlight advantages, disadvantages, uses and methods of application for various one- and two-part mold materials.

One-part mold materials usually present more disadvantages than two-part materials.

Polyteks two-part materials are tough, long-lasting, easy-to-use mold rubbers.

Uses Methods

One-Part Mold Compounds

Type Alginate Hydrogel N Wax Poly Skin-Wax Advantages Safe for body contact Disadvantages
Very limited life; dries out Gets model wet

Body molds Pour Single-use molds Layup Body molds Brush-on Single-use molds Dip

Safe for body contact Low cost Fast set Reusable

Low strength Limited use Must melt prior to use Not dimensionally stable Takes days or weeks to
make mold

Latex Poly Latex 60 Poly Latex False Face

High strength

Concrete Plaster statuary Limited resins

Brush-on Spray Dip

Oils can soften and

destroy molds

Blanket molds only with

shell required

Two-Part Mold Rubbers

Type Polyurethanes Poly 74, 75, & 77 Series Poly 81 Series Poly 72-40 Series Polygel Tin Silicones TinSil 70 Series Advantages Moderate to low cost High strength Many versatile varieties Disadvantages Requires careful
release agent May be moisture sensitive

Uses All materials

except molten metals

Methods Pour Brush-on Spray

No release agent
needed High strength Excellent chemical resistance

Higher cost Shrinks up to 1% on

curing

All materials
(especially resins and lowtemperature melting metals)

Pour Brush-on Spray

Limited cured storage

life

Platinum Silicones PlatSil 71 Series PlatSil 73 Series PlatSil Gel-10

No release agent
needed No shrink on cure Good cured storage life High strength Excellent chemical resistance

Higher cost Cure inhibited by some

surfaces

All material

Pour Brush-on Spray

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Mold Making Methods

Model Composition
A models composition or surface coating may restrict you to certain mold making materials. Certain mold materials do not cure properly over some model materials (i.e., platinum-cured silicones do not cure on sulfur-containing clay models). Sometimes, if the models composition presents a problem, it can be overcome by carefully sealing the model (see p. 11). Thoroughly review product technical bulletins to be sure that there are no compatibility issues between your model and the mold material youve selected. If your model is delicate or valuable, it is best to try the selected mold material on a small hidden area before you jump into mold making. Fragile models can be damaged in the mold making process. The resulting mold, however, can be used to make a reproduction out of a more durable material. [Note: If the model is a human body, there are obvious safety issues. Consider Hydrogel Mold Compound or Poly Skin Wax (see pp. 59-60).]

When using mold making or casting materials you are usually filling a given space. The lower the cost per cubic inch of material, the lower the cost of filling the space. Specific Volume, expressed in cubic inches per pound (in3/lb), is the key to calculating the real cost of a mold making and casting material. Some rubbers and plastics that have a low price per pound contain dense fillers such as powdered marble or silica. These fillers typically reduce the price per pound, but raise the price per cubic inch. Simple calculations reveal the real cost of your material in terms of cents per cubic inch. Poly 74 Series Rubbers (see p. 34) are low density and contain no heavy fillers. They yield 27.5 in3/lb. Poly-Fast 7240, a dense rubber, contains fillers and yields only 20 in3/lb -nearly 1/3 less rubber volume per pound! For example: An 80-lb trial unit of Poly 74-30 costs $336 or $4.20/lb ($336/80 lb). Dividing $4.20/lb by 27.5 in3/lb yields a cost of $0.15 per in3. A 49.5-lb trial unit of Poly-Fast 72-40 costs $194 or $3.92/lb ($194/49.5 lb). Dividing $3.92/lb by 20 in3/lb yields a cost of $0.20 per in3. Poly 74-30 = $0.15 per in3 Poly-Fast 72-40 = $0.20 per in3 At first glance it appears that Poly 74-30 is the more expensive product; however, to fill a given space, using Poly 74-30 actually costs nearly 25% less than higher density Poly-Fast 72-40 rubber. The photo below shows the dramatic density difference between these rubbers.

Cost per cubic inch is your real cost -price per pound can be misleading.

Model Shape and Size

The size, shape, and even location of your model may limit you to certain mold making materials and types of molds (i.e., a model with deep undercuts does not lend itself to a simple box mold). If you are restricted to a certain type of mold, then your choices of mold materials may be limited.

Cost
Both the volume of material needed and the price per unit volume must be considered in calculating project cost. The quantity of mold making material needed is dictated largely by the type of mold you choose to make -- a large model may mandate a brush-on mold since any other type of mold would require too much material. The quantity of material needed can be calculated by estimating the volume of mold making material needed (in cubic inches) and dividing by the specific volume (cubic inches per pound) of the material (see box to the right). To determine project costs more accurately, one also needs to consider the time it takes to make the mold (see below).

Time Considerations
Timing plays an important role in the selection of a mold making material. With some materials a mold can be completed in an afternoon (i.e., accelerated silicone and polyurethane mold rubbers), while with others, it can take weeks (i.e., latex rubber). To learn more about demold times, read the technical bulletins for individual products. Remember, the fastest material or method may not be the least expensive. Consider how long you intend to use and keep the mold. Some materials are only suitable for one casting (i.e., Hydrogel), while others will hold up for hundreds of castings (silicones and most polyurethanes). Also, consider library life: how long you expect the mold to remain useful after sitting on a shelf. Most properly cured rubber molds are useable for many years, but some degrade within 2 to 4 years (i.e., Poly 72-40 and TinSil rubbers). For molds with long library life, use polyurethane rubbers (except Poly 72-40) or PlatSil silicone rubbers. 4

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Mold Making Methods 5

SELECTING A CASTING MATERIAL

To select the best casting material for your project, you must consider several factors: mold composition and construction, required characteristics of the casting (i.e., weight, durability), cost, and timing. First, it is a good idea to familiarize yourself with the common casting materials and understand the general advantages and disadvantages of each. The most common and least expensive casting materials are gypsum plasters and cements, both of which are available in many formulas for various end uses. Waxes are castable, of course, but uses are limited by low hardness and high shrinkage. Low melting metals can be cast in heat resistant silicone molds. Epoxy and polyurethane systems are versatile and durable casting materials. Polyester resin is quite low in cost, especially if low cost fillers like sand, limestone or wood flour are added. The table below presents common casting materials suitable for use in molds made from Polytek flexible mold products.

Mold Material
Skin-Wax

Casting Material
Low-exotherm materials -polyurethane and silicone rubbers and select resins Materials that are not moisture sensitive -- wax, plaster, silicones and select resins Concrete, plaster and select resins Most casting materials are acceptable, except metals All casting materials are acceptable

Hydrogel

Latex Polyurethane

Silicone

Mold Composition
A molds composition may restrict you to certain casting materials. In a few cases, casting materials may rapidly degrade or even destroy the mold (i.e., exothermic epoxy resins will melt a wax mold). Carefully review product technical bulletins to be sure that there are no compatibility issues between your mold and the casting material. Molds made from Polytek products are non-porous and casting materials used in the molds should "cure" or set chemically. In most cases, air drying materials are not suitable since the rubber prevents them from drying except from the back. Water clay, paper-mache, and latex are often not suitable casting materials. The illustration above provides a general guideline regarding suitability of casting materials depending on mold composition. Disadvantages
Fragile High shrinkage Requires high heat to use Indoors only Brittle Heavy Rough surface Slow set Higher cost Expensive Difficult to use Strong odor Flammable Strong odor Health hazards Limited mass Moisture sensitive

Casting Material
Wax

Advantages
Easy demold

End Uses
Foundries Candles Resculpting Prototypes Parts Most indoor objects Moulding Statuary (indoor & outdoor) Architectural ornaments Many diverse uses (painting may be needed for outdoor use)

Vinyl Gypsum Plaster Concrete/ Specialty Concrete Design Cast and Forton MG Acrylic Resin

One-part liquid Fast Yields good quality Acceptable for outdoor use

Acceptable for outdoor use Clear

Polyester Resin Epoxy Resin Polyurethane Resin/Foam

Inexpensive Moderate price Moderate price Easy to use Very versatile

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Mold Making Methods Exotherm of Casting Material

Exotherm is the heat of reaction produced as a resin or rubber cures. Polyurethane rubbers generally have very little measurable exotherm. Poly 74-55 in a large mass may rise just a few degrees above the temperature of the Parts A and B before mixing. Epoxies, on the other hand, are much more exothermic and, if poured in too large a mass for the heat to dissipate, may get so hot that they boil and burst into flames. Therefore, casting epoxies in large masses is dangerous and must be avoided. Consider exothermic heat when selecting casting resins. If the casting is so thin that exothermic heat is easily dissipated into the mold, the resin will be slow to cure, but there will be no thermal shrinkage caused by gelling while hot then cooling. Slow curing in these cases can be overcome by using warm molds or using a faster curing system. Massive castings tend to build heat in the center of thicker sections and sometimes thinner sections of the same casting remain cooler. If the temperature difference is too great, distorted parts or shrink marks may be evident. Often, warm molds can help overcome this problem as can addition of fillers or use of slower curing systems. High curing temperatures shorten rubber mold life, so proper selection of casting systems results in best economy and longest mold life.

Weight of the Casting

Casting materials have different densities that affect the weight and feel of the final casting. For example, plaster and concrete are heavy, while resins are lighter. The weight of a casting can often be controlled by adding fillers to the casting material. Also, you can create a lighter, hollow casting, by using a "plug" to prevent casting material from filling the entire mold, or by laying up into or rotating a mold so casting material cures in a thin shell on the mold surface. These techniques are discussed on p. 10.

Exterior Durability of the Casting

Materials such as cement are fine for both indoor and outdoor environments, whereas most other casting materials need to be painted or sealed for outdoor use. Exterior castings are subject to elements such as UV light from the sun, rain, and freezing and thawing. Concrete and polyester resin castings are fine for interior and exterior uses. Polyurethanes, however, must be painted or sealed prior to being placed outdoors in order to avoid yellowing and chalking of the bare plastic, which occurs over time. Fillers, pigments and Poly UV Additive can be added to improve exterior performance (see p. 61 for information on Poly UV Additive).

Cost
Both the quantity of material needed and the price per cubic inch must be considered in calculating project cost. The quantity/weight of casting material needed is dictated by the volume of material needed (in cubic inches) divided by the specific volume (cubic inches per pound) of the casting material. Here is a general idea about the relative costs of casting materials.

To reduce costs and cast larger masses, ADD FILLERS to polyurethanes & epoxies.
Many fillers are suitable to add to liquid plastics to reduce costs and help dissipate exotherm, which can cause shrinkage and limit the size of the mass that can be cast at once. Heavy fillers absorb more exothermic heat, but result in a heavy casting. Lightweight fillers can make the casting lighter than wood so it will float and carve easily. Some fillers such as wood powder and nut shell flours may contain moisture and cause foaming of the plastic or other problems. Dry fillers that stir easily into the mixed resin are best. The cost per cubic inch of resin displaced is the real cost of these fillers. For example, some typical costs per cubic inch follow: Filler Dry Sand Bronze Powder Ground Limestone Extendospheres CG Q-Cel 2116 or 3M C/15 $/lb $0.05 5.00 0.15 0.50 6.00 Density (g/cc) 2.75 8.85 2.70 0.70 0.10 $/in3 0.005 1.590 0.015 0.013 0.022

COST

High Cost Medium Cost Low Cost

Unfilled polyurethanes and epoxies Filled resins, speciality concretes (i.e., Forton MG) Concrete, plaster, wax, filled polyester

Obviously, to determine true project cost one needs to consider the time it takes to make the casting (see below).

Time Considerations
Timing plays an important role in the selection of casting material. With some materials, a finished casting can be made in minutes (i.e., EasyFlo 60 Plastic); while with others, it can take days (i.e., concrete). The fastest material or method often is not the least expensive.

TIME

Slow Medium Fast

Concrete Plaster, wax, thin resins Polyurethane and polyester resins

Adding an equal volume of low cost filler to a Poly Plastic can cut the cost of the casting nearly in half! For example, one cubic inch of resin at $0.14 plus an equal volume of filler at $0.015 yields approximately two cubic inches costing $0.155 or about $0.07 per cubic inch for the mix.

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Mold Making Methods

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Mold Making Methods

TYPES OF FLEXIBLE MOLDS

There are two basic types of flexible rubber molds: block molds and blanket molds. Within these two basic types, there are numerous variations differing in both construction and complexity.

BLOCK MOLDS
Block molds are typically made by placing the model into a containment area (i.e., mold box) and pouring liquid rubber over the model. After curing, the rubber is removed from the model and the result is a single-piece, poured block mold. This is the simplest type of mold. Single-piece, poured block molds are best for models with a relatively flat base or back and no sharp undercuts that prevent the rubber from demolding from the model. This type of mold would be used for reproduction of a wall plaque. For a model with undercuts (i.e., the chin of a cherubs face) a softer rubber can be used or the mold may need to be cut to allow for removal of the model and castings: this is referred to as a split block mold. In some cases, the block mold may need to be cut into or poured in several pieces to allow for removal of the model and then carefully reassembled prior to casting: this is referred to as a multi-piece block mold. Sometimes, multi-piece block molds are made in sections, by pouring on one surface at a time, allowing to cure, then pouring on the adjoining surface against the previous pour. This technique is necessary when the model has details on all sides (i.e., does not have a flat base or back). Poured molds are sometimes free standing if the rubber is thick enough to hold its shape, but often a box or rigid shell is used with the mold to maintain its shape. Generally, the box or shell (mother mold) must be separate from the rubber mold in order to allow the mold to flex for removal of the model or casting.

Various molds and castings of ornate architectural elements and decor.

Poured mold materials generally pick up detail with fewer entrapped air bubbles than materials that are applied by brush or spray, except where bubbles on the surface of the rising liquid are trapped under a ledge such as under the chin of a head model. Tilting the mold box while pouring is a useful technique for preventing air entrapment. If this does not help, a brush-on mold, or pouring one section at a time may be advised. For diagrams depicting the procedures to make a single-piece poured block mold, a split single-piece poured block mold, and a multi-piece poured block mold, see pp. 17-18. A note on the terminology: Since a block mold is often made in box shape, it is sometimes called a box mold. However, this type of mold can be made in any appropriate containment area (i.e., a cylinder such as a piece of PVC pipe). Also, block molds are sometimes referred to as poured molds since this is the method used to make them.

Mold Complexity
Multi-Piece Poured Blanket Mold Poured Blanket Mold Complexity Sprayed Blanket Mold Brushed Blanket Mold Multi-Piece Block Mold Single-Piece Block Mold Contributing Factors: Size Location Shape Time Materials

Two-piece block mold

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Mold Making Methods

BLANKET MOLDS
As the name implies, blanket molds resemble a thin blanket carefully placed around the model. Blanket molds are made by either brushing or spraying the flexible mold material onto the model or pouring the mold material into a pre-constructed shell around the model. With a few mold materials (i.e, latex, wax), it is possible to make a blanket mold by dipping the model into the liquid material. Blanket molds are generally - to -inch thick. To hold a blanket mold in its proper shape after the cured rubber is removed from the model and during the casting process, a rigid or firm mold shell (mother mold) is required. Blanket molds are often mandated by the size and/or location of the model. Since blanket molds consume far less rubber than a conventional block mold, they are preferred for large or irregularly shaped models. Typically mold rubber is sprayed or brushed on large models. Often, blanket molds are the only choice for large, immovable models (i.e., large gargoyle high on a building facade). With some models, blanket molds can be made in one piece and lifted or peeled off the model and subsequent castings like a sock; this is sometimes called a glove mold. A bas relief or a figure with a pyramid shape (the bottom wider than the top) lend themselves to one-piece molds. Molds that are to be turned back on themselves and peeled off must be kept thin, usually less than 1/8-inch thick, to minimize stress and possible tearing of the rubber. As the mold is peeled off, it may need to be lubricated with silicone release or soapy water on the outside surface to allow it to slide easily against itself. For many types of models, the blanket mold must have a split down one side to allow for easy removal of the model and to reduce the chance of tearing the mold. The rubber at the end of the seam may be reinforced with fabric at the top where a tear may be likely to develop in the mold. For complex models, blanket molds can be made in two or more pieces. Shims or flanges are used to create seams or parting lines where required on blanket molds and their shells. A split blanket mold can be made by affixing a thin shim of aluminum flashing, cardboard or stiff plastic film to the model projecting several inches, applying release, and brushing/spraying the rubber up against the shim. The shim should have keys or indentations to allow the rubber flanges of each mold section to
One-piece, Polygel brushed blanket mold.

lock together to maintain position with respect to one another and to the shell. With the development of self-thickening and thixotropic (see definition below) mold materials, making brush-on and sprayed blanket molds has become routine. Not only do brush-on and spray molds use less rubber, but they are generally faster to make than poured blanket molds and offer the moldmaker visual control of rubber placement. In the past, blanket molds were often made by dipping the model into or brushing on latex. Since each layer of latex must dry overnight before the next layer can be applied, building up an adequate thickness of latex for a useable mold can take weeks. Trying to brush-on a pourable liquid without thickening usually produces less than satisfactory results since the the liquid flows off vertical surfaces. In order to make molds faster, moldmakers add fillers to pourable mold rubbers in order to thicken the uncured mix to a consistency that can be applied by brush. For example, Poly 74-30 Liquid Mold Rubber can be mixed with fumed silica (i.e, Cab-O-Sil) to make brush-on blanket molds (see photograph on p. 21). Many customers use this method because it allows them to thicken the rubber to the exact consistency that is desired and is the most economical method of making brush-on molds. For more information regarding thickening of liquid mold rubbers, refer to the product descriptions (see pp. 34-45) or call Polytek Customer Service. In 1992, Polytek received a patent for the Polygel technology, which enables the mixed Parts A and B liquids to immediately react to form a gel with a consistency perfect for brush-on application. Polygel 35, 40 and 50 Liquid Mold Rubbers are ideal for brushing on a properly prepared model right after Parts A and B are mixed. In addition, certain Polygel products have been specially formulated for spray application (Polygel Spray 35, Polygel Spray 50 and Quick Spray 50). See pp. 36-37 for information on Polygel products. Whether using liquid rubber thickened with Cab-O-Sil or the advanced Polygel products, a most important characteristic of the mixed mold material for brush-on or spray application is thixotropy (see box). To make a brush-on or spray-on blanket mold, the rubber must be thick enough to not sag after

THIXOTROPY:
The key to successful brush-on molds. Thix.ot.ro.py \thik-`so-tr -pe\ n [fr. Gk thixis act of touching]: the property of various gels becoming more fluid when disturbed (as by mixing) -- thixotropic adj
(Websters Ninth New Collegiate Dictionary)

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Mold Making Methods

have projecting keys or rubber snaps, on its flange and back so that the mold locks into the shell to prevent flopping out of position. [Tip: Buttons of rubber, cast in advance in plastic pill holders, can be bonded onto the last coat of the mold rubber so that the shell is formed around them holding the mold in position in the shell.]

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Mold Making Methods

Both brush-on and spray blanket molds are most easily made with Polygel Liquid Mold Rubbers.
application on the model, but also must be more fluid when it is mixed or moved around the model surface with a brush. Polygel products are thixotropic: they are thick enough to resist sagging when applied to a vertical surface, but are fluid when mixed and moved around the model surface. Basically, the more energy you put into a thixotropic material, the lower the viscosity -- the faster you stir it the more fluid it seems. A good liquid rubber for brush-on molds must become thixotropic shortly after Parts A and B are mixed together -- thats Polygel. For diagrams depicting the procedures to make a single-piece blanket mold, a split single-piece blanket mold, and a multipiece blanket mold, see pp. 18-23.

MOLD SHELLS (AKA MOTHER MOLDS)

A mold shell, also known as a mother mold, is not a production mold but rather a shell that is required to hold the flexible rubber mold in its proper shape. The shell and mold are used on the production line. Mother molds are sometimes used with block molds and are nearly always used with flexible blanket molds. Mother molds can be made of plaster, plaster and hemp, polyester resin and fiberglass, urethane foam, or one of Polyteks firm liquid rubbers or rigid liquid plastics. Poly 15 Series Liquid Plastics (15-6, 1511 and 1512X) and Polygel Plastic-75 make tough, durable, lightweight mold shells in a matter of minutes! For more information on 15-Series Liquid Plastics see p. 49; for Polygel Plastic-75, see p. 55. The mother mold is usually made over and is removable from the rubber production mold. Care must be taken so that a rigid shell does not lock onto undercuts in the block or blanket mold. All such undercuts must be eliminated or the shell must be made in multiple pieces to work around them. In certain situations, a firm but flexible mother mold can offer a good solution to undercuts. A flexible mother mold, such as one made of Poly 74-30 Mold Rubber, can be pulled off simple undercuts. You may use a little more rubber, but you can save lots of labor. Mother molds are often two or more pieces even when the mold is one piece. The shell for a split mold would part along the line of the split in the mold. Parting lines for shells can be established using plasticene strips applied to the cured rubber, building up the shell against one side of the strip, removing the strip, applying release and building the other half of the shell. When complete, the sections of the shell press the flanges of the rubber together like a gasket, keeping the parting line tight and inconspicuous. If a brush-on mold is large, the rubber should

In the case of a poured blanket mold, the mother mold is typically made before the rubber mold is made. After the mother mold Polygel rubber mold and resin is cured, it is positioned over shell made of Poly 15-6 Liquid the model and the liquid Plastic thickened with Poly Fiber. mold rubber is poured into the void between the mother mold and model to make the blanket mold. For more on this technique, see pp. 22-23. A mother mold can last indefinitely and can help prolong the life of a mold since a rubber mold stored in its shell can maintain exact dimensions. The mold in its shell will last many years if it is stored in a cool, dry area out of sunlight. Still, when the rubber fails (as all flexible molds eventually do) the shell is simply repositioned over the model and a new mold is poured, ready for use the next day.
These three photos illustrate the construction of a poured blanket mold. First, the model, a gargoyle face, is covered with clay. Next, a rigid, plastic mold shell (i.e., Poly 1512X, see p. 49) is constructed over the clay blanket. After the plastic cures, it is removed and the clay is removed from the model. Then the plastic shell is repositioned over the model and liquid rubber (i.e., PlatSil 71-11, see p. 43) is poured through an opening in the shell and covers the model. Once the rubber cures, the model is removed and the mold is ready to use. Cast away!

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TYPES OF CASTINGS
There are numerous types of castings and casting methods. Castings vary by the type of material that they are made of (see p. 2), and by the method employed to make them. The table below summarizes the most common casting methods along with the advantages and disadvantages inherent in each technique and the products for which one might use each method. The photo to the right shows numerous castings made from various Polytek casting plastics.

Casting Method
Solid Pour
Material is poured into the mold resulting in a solid casting.

Advantages
Fast

Disadvantages
Heavy Possible high cost

End Uses
Small objects Industrial tools

Gel Coat and Layup

A thin surface coat is applied and subsequent layers of reinforcing material like fiberglass mat and resin are built up to a thin, strong laminate. Lightweight Less material used High quality surface Time consuming Rigid molds Mold shells Large objects Bonded bronze

Slush Cast
Material is manually rotated in the mold creating a thin layer resulting in a lightweight hollow casting. Lightweight Less material used Time consuming Art objects Bonded bronze

Rotational Cast
A closed mold is rotated by machine as a small amount of material coats the surface and sets, resulting in a hollow, lightweight casting. Fast Easy Lightweight Six-sided parts Need a machine Larger statuary Hollow parts

Injection
Liquid is forced into the mold under pressure. Quality parts Requires setup time Often need a machine Manufactured parts

Vacuum and Pressure

Bubbles are eliminated, resulting in perfect, high detail parts. Used in conjunction with solid pour. Quality parts Requires setup time Need vacuum pump/pressure pot Prototypes Figurines

Direct Layup/Spray - No Mold

Material is spread over a screen armature. Surface detail is sculpted into the wet material or plastic hardcoat sprayed over carved foam substrate. Lightweight Less material used Time consuming Amusement/theme parks Sculpted rocks

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MOLD MAKING PROCEDURES

This section guides you from model preparation through finishing your casting. The directions provided here are general in order to be helpful regardless of what mold making and casting materials you choose and what type of mold or casting youre making. The following sections are presented in the order that your project should proceed. Diagrams that depict procedures for making a few different types of molds are presented after the complete text description (see pp. 17-23).

If you dont follow directions ... there is a lot that can go wrong ...

Improper Mix Ratio - Slow, non-curing or

soft material can result if two-part materials are not weighed or measured accurately. Always use an accurate scale (see accessories, p. 63). Do calculations carefully and double check the mix ratio listed on labels and product literature.

SAFETY FIRST!
Before you even open your containers of mold making or casting materials, understand the hazards of the materials that youll be working with.

Release Agent or Sealer - Incorrectly

applied or missing, or use of the wrong sealer or release can result is sticking or damage to the mold/casting. If youre not sure that youve properly sealed/released a model, make a test cure. Too much release agent can cause pinhole surface defects or bubbles in the mold and/or casting.

Read material safety data sheets (MSDSs) and product labels - MSDSs are sent with every Polytek
product and contain very important safety information. Also, Polytek product labels have hazard warnings and precautionary statements. Read the MSDS and labels carefully so that you can use Polytek products safely. If you do not receive MSDSs with your shipment, call Polytek Customer Service and they will promptly get them to you.

Low Temperatures or Demolding Too Soon - Deformed parts can result. Fluctuating
temperatures during curing can cause bubbles and dimensional changes.

Understand health hazards - Some uncured Polytek

products can cause skin, eye and respiratory irritation if improperly handled. Also, a few uncured products can cause dermal and respiratory sensitization (i.e., allergic reactions) in sensitive individuals. Avoid skin and eye contact and breathing vapors from uncured materials. Do NOT use Polytek products where food or prolonged body contact may occur.

Leaking Mold, Boxes or Shells - Your pour

can spill, wasting material and time. Use mechanical fasteners and hold downs and be sure that seams are tight and sealed.

Material Hardens Before Its In Place Avoid delays once material is mixed. Watch a clock!

Use personal protective equipment (PPE) and engineering controls - Follow recommendations on
product MSDSs for use of PPE such as gloves, dust masks, safety glasses or goggles, aprons, and, in limited cases, airpurifying respirators with organic vapor cartridges. Use products in areas with adequate ventilation such as a large open room with air circulation.

Unmixed Material - Streaks of uncured or

soft areas and/or gas bubbles can develop several weeks after curing if Parts A and B are not thoroughly mixed. Poorly mixed material is often from the sides and bottom of the mixing container.

Incorrect Material Selected - Choosing

the wrong material can result in sticking or damage such as staining or softening a model, mold or casting.

READ DIRECTIONS
All too often, projects are spoiled because, in enthusiasm for completing a project, important directions are not followed. Before starting your project, read product technical bulletins and label directions thoroughly. Call Polytek Customer Service if you have any questions.

Material Not Stirred Before Use - Some

components (Part A or B) must be stirred before use. If the component is not carefully stirred before mixing with its counterpart, soft cures or bubbles can result.

MODEL PREPARATION
Porous models, such as wood, plaster, stone, pottery or masonry, must be sealed, then coated with a release agent such as Pol-Ease 2300 Release Agent or PolyCoat.
Sealing prevents rubber or resin from penetrating pores in the model surface. Several coats of paste wax, allowed to dry and polished or melted paraffin, petroleum jelly, lacquer, shellac,
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Contaminated Material - Moisture or

other foreign contaminants can spoil the cure of materials. Freshly opened containers and clean tools are important.

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Mold Making Methods Important Terms

paint, PVA (polyvinyl alcohol solution), and potters soap on plaster all work well for certain surfaces and mold rubber or resin combinations. Some rubbers (i.e., Poly-Fast 72-40) contain materials that dissolve or soften lacquer and paints. For them, wax or shellac are often used as sealers. Polyurethanes bond tenaciously to shellac, however, so if shellac is used as the sealer, release agent must be very carefully applied over it. Bare plaster is best sealed with potters soap (or Murphys Oil Soap) lathered into the damp surface of the plaster with a soft brush, rinsed and repeated several times, then polished with a soft brush or cloth. Only use soap on plaster, it is not suitable for sealing with other materials. If the plaster is dry, it should be wet for several seconds under running water prior to soaping. Moist water clay, another special case, can be sealed and released with Pol-Ease 2350 Release Agent or by spraying on a 10% solution of petroleum jelly in mineral spirits, made by warming and melting the petroleum jelly and stirring in mineral spirits. [Note: Use extreme caution since mineral spirits is highly flammable.] Then apply the solution using a plant spray bottle, brush out and allow to dry. This prepares the water clay for contact with most mold rubbers. If the water clay is completely dry, it should be sealed and coated with release as for terra cotta.

Cure time is often longer than demold time, sometimes even though a product feels cured and can be demolded, curing may continue for up to a week. Demold time is the soonest a cured product can be removed from the mold if it has been at recommended temperature. Demolding castings as soon as possible helps to extend mold life. Thin castings may require more time in the mold before demolding. Density is the weight of material that fills a given space. Water has a density of 1.0 g/cc and a pound of water takes up 27.5 cubic inches. Thus a pound of material with a density of 2 g/cc will only fill half the space or 13.75 cubic inches. When buying mold rubber or casting resin you must consider the price per volume, as the price per pound can be misleading. (See box on Cost per cubic inch, p. 4.) Elongation, reported in percent, is the length the material stretches before breaking. Hardness is measured with a Durometer. It pushes a needlelike probe into the rubber as it is pressed against it. The farther the needle penetrates into the sample the lower the reading. The Shore A scale is used for rubbers and the Shore D scale is used for plastics. Both scales go from 0 to 100. A rubber with a Shore A hardness of 0 is like warm chewing gum. Shore A10 to 20 is about as soft as any mold rubbers can be. Shore A50 rubber is like a car tire. Above A80, rubbers feel more like a plastic and may measure on the low end of the Shore D scale. Shore D90 is about as hard as plastics get. Pour time, working time, pot life or gel time give you an idea how much time youll have to work with a material from the time mixing begins until it gels. Most materials should be in place well before the end of this time to allow good flow into detail and for air bubbles to rise and break. Rheology describes how a liquid flows. A liquid is Newtonian if it flows and levels, even if very slowly. Pourable mold rubbers should be Newtonian. Brush-on mold rubbers may be thixotropic, that is they flow when brushed/troweled, but when undisturbed they stay where they are placed (see box on p. 8). Shrinkage is a reduction in size, which occurs with some plastics during cure or some rubbers after prolonged use. Casting materials draw oily materials out of the rubber causing it to shrink. Products that develop heat during cure shrink as they cool. The degree of shrinkage increases with the temperature increase during cure. Some plastics get warmer in the center than against the cool mold surface and tend to cause the still liquid resin against the mold to sink. (See box on Exotherm, p. 6.) Polytek products that stay cool during cure do not shrink while curing. Tear strength is reported as the force needed to tear a split one-inch long in a piece of material. Higher elongation rubbers generally have a higher perceived tear strength. Tensile strength is the force required to break a piece of material when pulled. It is reported in pounds required to break a one-inch square specimen of material. Viscosity, reported in centipoise (cP), describes if a liquid is thick or thin. Water is low viscosity (1 cP), while pancake syrup is higher (1000 cP), and honey is even higher (10,000 cP). Temperature affects viscosity -- the lower the temperature, the higher the viscosity. For best flow into detail, Polytek materials should be at least room temperature.

Pol-Ease 2300 Release Agent must be applied to nearly every surface before pouring or applying liquid rubber (except
silicones) or resin. It should be sprayed evenly and then gently brushed out with a dry brush to pick up any excess and to spread the release over any spots missed by the spray. The brush should be wiped with a paper towel periodically to prevent too heavy a coating being left on the surface. Too much release can cause pinhole defects in the surface of the liquid material poured against it. The coating of release should be allowed to dry for about 15 minutes prior to pouring. Silicone-based release agents like Pol-Ease 2300 may interfere with the cure of silicone mold materials. When pouring silicones, use Pol-Ease 2350 on surfaces that the liquid silicone will contact. Consider PolyCoat as a semi-permanent, dry sealer and release when using polyurethane rubbers.

If you have any question about the compatibility between the rubber and the prepared model surface, perform a test cure on an identical surface to determine that
complete curing and good release are obtained. Some materials such as sulfur-containing modeling clays and wood knots, inhibit curing of some rubbers and plastics.

Securely fasten and seal side boards or shells to the base to prevent leakage. Seal and apply release on all side
boards and shell interiors. Petroleum jelly is excellent for most non-critical surfaces like these, unless the material gets warm enough during cure to melt the petroleum jelly. Pol-Ease 2300 Release Agent is more heat resistant, but is not self-sealing, so surfaces must first be well sealed. Porous models must be vented from beneath to prevent trapped air from forming bubbles in the rubber. A hole at least -inch in diameter should be drilled through the base board into the porous model. The base of the model must be sealed around the perimeter with Poly Plasticene or glue to prevent liquid rubber from leaking under the model and through the vent hole.
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MIXING THE MOLD RUBBER

Have all materials at room temperature (75F) before mixing. It can take 24 hours for a 5-gal pail of material to warm
up to room temperature in the winter.

Have all materials and equipment clean and ready.

Time is critical to success. You do not want to go searching for tools after you have mixed Parts A and B.

Stir individual components before use if recommended. Some materials separate and will not cure properly if separated material is used. Weigh and measure accurately. Mix Ratios Vary! Check
the mix ratios for the specific product you are using. For liquid rubbers, most mix ratios are expressed by weight. Carefully weigh Parts A and B in proper ratio. Weighing components on an accurate scale is a must. Only materials with a mix ratio of 1:1 by volume can be measured by volume. Polytek does not recommend trying to measure any other mix ratio by volume. Before starting to mix rubber, have all materials at hand and at room temperature (75F). A Poly Paddle is an excellent tool for handmixing liquid rubber without introducing excess air into the mix. Scrape the sides and bottom of the mixing container thoroughly several times while mixing.

Close containers tightly after use. Most materials are

usable at least six months to a year after shipment if unopened. Uncured polyurethanes, epoxies and some silicones react with atmospheric moisture and, therefore, should be used up as soon as possible after opening. Before resealing, Poly Purge Dry Gas Blanket (see p. 63) can be sprayed into open containers to displace moist air and extend storage life.

Time your actions with a clock. Start timing when you start
mixing. Try to have material poured and in place before half of the working time has elapsed so there is plenty of time for bubbles to rise away from the mold surface.

Carefully Adhere to Mix Ratios!

The chemistry of polyurethanes, silicones, and epoxies must add up.
Unlike polyester resins, the recommended mix ratio of polyurethanes, silicones, and epoxies cannot be varied without causing changes in the physical properties of the cured material. This is because to cure 100 reactive groups of Part A, 100 reactive groups of Part B are needed. If 100 reactive groups of A weigh two pounds and 100 of B weigh one pound, then the mix ratio must be two A to one B (2A:1B), by weight. Generally, if excess B is used the cured plastic will be softer. If excess A is used the plastic will be harder. But off-ratio mixes can cause other problems, such as no cure at all, dimensional instability, or short storage life of the cured rubber.
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Mix well, but avoid whipping air into the mix. Scrape the
sides and bottom of the mixing container thoroughly several times while mixing. A Poly Paddle is invaluable for good mixing. Sometimes, to insure that no unmixed material is clinging to the sides or bottom, the mix can be poured into a clean container and mixed again for 1 to 2 minutes before pouring. For large mixes (i.e., >30 lb), a Jiffy Mixer (see p. 62) on a variable speed drill can be helpful, but care must be taken not to whip air into the mix or scrape the jiffy mixer blade against sides and bottom of the container.

Avoid being rushed. Careful planning allows for a deliberate pace without making mistakes.
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APPLYING THE MOLD RUBBER

Most often liquid mold rubber is poured over the model surface. With the development of Polygel products, however, applying liquid mold rubber to the model surface by brushing or spraying is becoming increasingly common. No matter how the liquid rubber is applied, one key is to avoid air entrapment. For poured molds, the liquid rubber should be poured in a steady stream into one corner of the mold box, allowing the liquid to flow over the model surface pushing air out ahead of it. In some cases, where there is exceptionally fine detail, some moldmakers feel that applying a small amount of mixed rubber to the surface and brushing or blowing it into the detail with low pressure air before pouring the bulk of the mix helps to ensure that the liquid pushes all the air out of the crevices. Caution must be taken that brushing does not actually push the liquid through the film of release agent on the surface, causing sticking, or that release does not float to the top of the brushed liquid, preventing

Mold rubbers are typically applied to a model by pouring, brushing, or spraying. Liquid mold rubbers with thixotropic properties are ideal for brush and spray application. Think Polygel.

How Much Liquid Rubber Do You Need?

Poured Block Mold - Box Shape
1. Calculate the volume of the box in cubic inches (in ). V=lxwxh where: l = Length w = Width h = Height
e.g., 10 in x 5 in x 5 in = 250 in3
3

Poured Block Mold - Cylinder Shape

1. Calculate the volume of the cylinder. V= x r2 x h where:

= 3.14
r = Radius ( diameter) h = Height

e.g., Using a 10-in tall section of 5-in diameter PVC pipe: 3.14 x (2.5 in x 2.5 in) x 10 in = 196 in3

2. Estimate the volume of the model. e.g., 8 in x 3 in x 3 in = 72 in3 3. Subtract the estimated volume of the model from the volume of the box. e.g., 250 in3 - 72 in3 = 178 in3 4. Use specific volume data (refer to Technical Bulletin for specific product) to convert the volume to quantity of liquid rubber needed in pounds. e.g., Using specific volume of Poly 74-30 Liquid Rubber (27.5 in3/lb): 178 in3 27.5 in3/lb = 6.5 lb Rubber

2. Estimate the volume of the model. e.g., 8 in x 3 in x 3 in = 72 in3 3. Subtract the estimated volume of the model from the volume of the cylinder. e.g., 196 in3 - 72 in3 = 124 in3 4. Use specific volume data to convert the volume to quantity of liquid rubber needed in pounds.
e.g., Using the specific volume of Poly 74-30 Liquid Rubber of 27.5 in3/lb: 124 in3 27.5 in3/lb = 4.5 lb Rubber

Note: For the hypothetical model above, far less liquid rubber is needed for the cylindrical mold. Choose your containment area carefully.

Brushed/Sprayed Blanket Mold

1. Estimate the surface area of the model. Depending on the
complexity of the model, this can be difficult and it may be necessary to consider a model in sections and add up all surface areas. If the model is basically rectangular, use the surface area equation for a rectangle; if cylindrical use the surface area equation for a cylinder (A = 2r2 + 2rh). Multiply the surface area by the thickness of the blanket mold (usually 0.25 in to 0.38 in) to determine the volume of liquid rubber needed. Use specific volume data to convert the volume to quantity of liquid rubber needed in pounds

Poured Blanket Mold

Poured blanket molds are usually made by covering a model with clay, making a shell, removing the clay, and filling the area once filled by clay with liquid rubber. Therefore, the volume of clay equals the volume of liquid rubber needed. Using the weight of the clay, calculate its volume by multiplying by its specific volume. Divide the volume of clay by the specific volume of the liquid rubber to get the weight of rubber needed. e.g., If a 2-lb block of clay was removed from the model: 2 lb x 18.4in3/lb = 36.8 in3 clay 36.8 in3 x 27.5 in3/lb* = 1.3 lb Poly 74-30 Rubber * Specific volume of Poly 74-30 Liquid Rubber

2.

3.

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adhesion between the poured material and the brushed material. For more information on applying liquid mold rubber by brush or spray, refer to Polygel product information (see pp. 36-37). If a super smooth mold back is desired, a light spray of Pol-Ease 2300 Release Agent on the top surface of the liquid just before it gels breaks most of the surface bubbles.

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CURING THE MOLD

Cure at the same warm temperature that all your materials were when mixed. Temperatures below 65F lengthen the time required for proper curing and may spoil the cure of some materials. Placing the poured mold or casting in a warmer area than the materials were when they were poured, can cause problems because changing temperatures while the material is setting can cause bubbles or distortion. Check product technical bulletin for proper cure time. Demold carefully as the material is still more tender than it will be a few days later. Bending or forcing a material while it is still only 90% cured can cause distortion that may not recover.

This blanket mold of a baluster is stored properly in its mold shell. The thin mold of PlatSil 73-45 is supported by a firm shell made from Poly 75-80 Liquid Rubber.

STORING THE MOLD

Proper storage of molds cannot be overemphasized and is the key to extended library life -- the time that a mold remains useful after storage. Some rubber molds, if stored properly, can have a library life of ten years or more. Store molds in their original, undistorted shape. Molds should be left in the mother mold, mold box or on a surface that causes the least distortion possible. If rubber is left in a distorted shape for any length of time it can take a permanent set and may never recover to its original shape. If a blanket mold is stored in a mother mold/shell made of porous material, such as bare plaster, the shell surface that contacts the mold must be sealed (e.g., with shellac). Sealing the shell prevents it from absorbing oils from the mold rubber which, in turn, can cause mold distortion. Do not allow molds made of one type of rubber to remain in contact with molds of other rubbers as migration of oils or plasticizers from one to another can cause swelling, shrinkage, or distortion. Poly-Fast 72-40 molds may soften over a period of 2-4 years. TinSil silicone molds may embrittle (i.e., lose tear strength and elongation) over a similar period. These mold materials should not be selected if long library life is required. Molds should be stored in a cool, dry area and out of the sunlight, which can degrade the surface.

USING THE MOLD

More rubber molds fail due to poor handling than by wearing out. Proper design, careful handling and attention to detail prolong mold life. When casting plaster, wet the rubber mold with Pol-Ease Mold Rinse or a 1% detergent (e.g., Ivory Liquid) solution in water before pouring the plaster. Wet the mold by dipping or spraying. Pour the plaster on the wet surface. [Note: Detergent is chemically different from soap. Do not use soap -- Ivory Liquid is a detergent.] When casting plastics in polyurethane or silicone molds, first coat the mold with a release such as Pol-Ease 2300 Release Agent. Release agent is not always needed in silicone molds. Spray a light even coat of Pol-Ease 2300 on the mold surface and then carefully brush the surface with a clean, dry brush to pick up any excess and cover any missed spots. PVA is a barrier to migration of plasticizers and chemical attack by harsh casting resins. Poly-Fast 72-40 rubbers contain plasticizers that can soften resin surfaces producing soft or sticky castings. If resins are to be cast in 72-40 molds, first coat the mold surface with PVA and allow to dry, then lightly spray with an even coat of Pol-Ease 2300. This surface treatment often acts as a barrier to the plasticizers. PVA can be washed off castings with soapy water. PVA also prolongs the life of polyurethane molds when casting polyester resins. For long mold life, avoid exposing rubber molds to strong solvents, oils or cleaners. Sprayed release agents reduce solvent exposure as compared to brush application.

Colors for Polytek Products

Most Polytek Liquid Rubbers & Plastics can be colored with the use of proper dyes or pigments. PolyColors, reactive liquid dyes available from Polytek in red, green, yellow, blue, brown and black, can be used in most Polytek polyurethane products. In addition, PolyColors can be added to certain silicones in small concentrations. Polyurethane rubbers and plastic can be lightly tinted or made vibrant and dark in color by using PolyColors up to 3% by weight of the total liquid mix. PolyColor Brown is excellent for creating a base color when making cold cast bronze parts. PolyColor Black can be used to make even the whitest plastics true black. Since PolyColors are dyes, not pigments, they mix in easily and do not settle in the liquid rubber or plastic when properly mixed. Use PolyColors individually or in combination to make any color imaginable. For product information, see p. 61.

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painting by detergent washing. If a prime coat is desired on the cast part, a barrier coat can be sprayed on the mold before casting. Paint enhances and protects plastic castings and is necessary for best exterior durability.

CASTING & FINISHING

For simple solid casts, the flexible mold and shell (if required) are positioned so the opening is level and release agent, barrier coat or rinse is applied, if necessary. The casting material is poured right to the top edge, vibrated if necessary and allowed to cure. Most casts should be removed as soon as they are adequately set, since longer residence times can damage some mold materials. Use of vacuum or pressure (see box below), brushing, spraying or heated molds are all helpful techniques to eliminate bubbles and achieve perfect casts of highly detailed parts, but simple pours are often adequate. Trim and touch up, is easiest while the casting is warm and is best done just after demolding. Remove release agent prior to

CLEANUP
Tools should be wiped clean with paper towels before the rubber cures. Casting plastics are extremely difficult to remove from tools once cured. Be sure to clean tools as soon as possible. Denatured ethanol is a good cleaning solvent, but it must be handled with extreme caution owing to its flammability and health hazards. Work surfaces can be waxed or coated with PolEase 2300 Release Agent so cured rubber and plastic can be removed.

VACUUM & PRESSURE CASTING

Perfect Castings Made Easily!
Although many excellent bubble-free molds and castings are made with Polytek rubbers and resins every day, trapped air bubbles create the most common defects. Proper use of vacuum or pressure can eliminate bubbles from some kinds of castings and molds and is often cheaper and easier than you might think. The following applies only to non-porous molds and models -- porous materials such as wood and plaster do not lend themselves to use of vacuum and pressure.

An alternative to a traditional vacuum pump is a venturi vacuum pump from Vaccon Vacuum Products. This device is attached to a vacuum chamber and an air compressor. The high volume air from the compressor flows past the double venturi, creating a negative pressure area, which in turn evacuates the chamber. For some applications, the venturi pump is a less expensive and effective option. For more information, go to www.vaccon.com.

Pressure
Using pressure to eliminate bubbles can be even more useful. The process is like reversing the opening of a bottle of soda. When pressure is applied to liquid rubber or resin, small bubbles are forced into solution and disappear. To accomplish pressure casting, pour the resin or rubber and place the whole mold in a pressure pot before the material begins to set. Fasten the lid and pressurize to ~60 psi with compressed air or nitrogen. Allow the cure to take place under pressure. You will be amazed with the results. Inexpensive pressure pots typically used by spray painters are available from paint supply stores and industrial supply houses such as Grainger. Caution: Vacuum and pressure systems can be dangerous. If you have any questions about the construction or operation of your vacuum or pressure system, consult a qualified engineer. Never use glass parts unless they are certified for the purpose.

Vacuum
Using vacuum to pull air bubbles out of mixed liquid rubber or resin can often be very helpful. Place the container of mixed liquid rubber or resin in a vacuum chamber and draw about 28 inches mercury so that the largest air bubbles rise to the surface. You must perform degassing while the mix is still liquid. Do not attempt to vacuum degas Polytek rubbers or resins with short work times -- this can result in creating more bubbles. Some liquids rise 2 to 3 times their original volume during degassing, so use a container with adequate head space. Once degassed, the liquid should be poured carefully so that air is not reintroduced into the mix. Simple vacuum chambers can be constructed from pressure pots as well as from sturdy commercial cooking pots. Its best to have a transparent cover. Vacuum pumps can be purchased from laboratory equipment dealers. A vacuum pump that is too small with insufficient capacity can be a frustration. You may find your material gelling before it is free of bubbles. Buy a large enough vacuum pump that will get down to maximum vacuum quickly so you can degas and pour before your mixed material thickens or gels. A Welch Model 1397 can often be purchased from equipment dealers for ~$3,000 new or ~$1,500 used. It pulls 17.7 CFM and works well with a 40-quart pot. 16

Welch Model 1397 vacuum pump with a 40 quart pot and lid made with Poly-Optic 1410 Clear Casting Resin.

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POURED MOLDS
One-Piece Block Mold
To make a poured block mold the model must be securely fastened (e.g., screwed or glued) to a base board. Kitchen countertop sink cut outs make excellent base boards. If the model is porous, a vent hole should be drilled through the baseboard to the model to allow air to escape. Sides of the mold containment area must be positioned and sealed to the base board (e.g., with plasticene or hot melt glue) so that liquid rubber cannot leak out. If the mold will be used without being placed in a box for support, then be sure to position the sides far enough from the model such that the rubber mold will be thick enough that it will not deform when it is full of casting material (at least 0.5-inch thick). Sometimes a strap is placed around the finished mold box to ensure that it all holds together. Once the model and the
Poured mold rubber

Sealed and released model

Screw model to base

Vent hole

base and sides of the box are properly sealed and released, slowly pour liquid rubber directing the flow to the bottom of the box and being careful not to trap air bubbles as the liquid rises. The rubber should be at least 0.5 inches above the highest point on the model (mark the mold box before you start pouring liquid rubber).

Cut Block Mold

A block mold can be cut when cured to make a split or multipiece mold. With some models, the mold must be cut to allow for removal of the model. Sometimes the cut is simply a single slit up one side of the mold, while in other cases a single-piece block mold can be cut into multiple pieces to create a complex multi-piece mold. In either case, after the model is removed, the mold is reassembled by carefully lining up the seams and usually returned to its box to hold it together before casting material is poured into the mold. For a successful cut block mold, the key is in the cutting. First, select a rubber with an appropriate hardness for cutting (i.e., Poly 74-30, soft Shore A30). Next, carefully evaluate where the cut(s) will be made (i.e., possibly up the back of the head, not on the face) and how many cuts are required. The cutting locations Split Block Mold
This head mold is cut from a cylinder of Mold cured rubber. The Strap containment area is Rubber a piece of PVC pipe sealed to a baseboard with plasticene Model or hot-melt glue. After the rubber cures, the pipe is removed from the base and cut with a saw to remove the mold. The rubber is cut with a mold key knife in a predetermined location to make a slit that allows for removal of the model. To avoid damaging the model, the first cut should not go completely though to the model, but rather the final cut through is made with a razor. When casting, the seam is carefully realigned and the mold is strapped together. The mold is inverted and casting material is poured into the opening. www.polytek.com

should be decided before the mold rubber is poured, marked on the mold box and then transferred to the cured rubber mold. To cut the mold, use a mold key knife (see p. 62), which has a sharp blade with a groove that creates a tongue and groove effect in the cut rubber. This makes reassembling the mold with the seams properly aligned possible. Vents and pour holes can be cut or drilled into the cured rubber, or can be formed with rods or plasticene prior to pouring the rubber. When casting, cut block molds are reassembled and typically placed back into the containment area with the pour hole at the top for filling with casting material. Sometimes, block molds poured as one piece are the fastest to make even for oddly shaped models; but they require more liquid rubber than blanket molds. Making quality, multi-piece block molds requires considerable practice and expertise. Multi-Piece Block Mold
Chunk cut out to remove ears

Chunk cut out to release front end

Vent

Plug cut out from between legs

Split to remove tail

This horse mold is cut from a single block of mold rubber. After pouring, curing and cutting the mold, it is reassembled and placed back into the mold box upside down for casting. Casting material is poured through the feet. As an alternative, the mold of the horse model could be made as a blanket mold poured into a pre-constructed shell -- this would mean easier cutting of the thinner blanket mold and using less mold rubber.

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POURED MOLDS (CONTD)

Block Mold Poured in Two Pieces
A block mold can be made by pouring two pieces of the mold separately. First, one portion of the model is embedded in clay up to the desired parting line. Then liquid rubber is poured over the properly prepared, exposed portion of the model (1). After the rubber cures, the clay is removed and release agent is applied to the other side of the model and the cured rubber surrounding it. Rubber is then poured over the second half of the model (2). Once cured, a pour hole is cut through the rubber mold and, if necessary, vent holes are drilled through high spots in the mold to eliminate the possibility of trapped air bubbles. The mold is repositioned in its box and is ready for casting (3).

positioning key

clay

mold rubber

First pour

Ready for second pour

pour hole vent

vent

Mold ready for casting

BLANKET MOLDS
Poured Blanket Mold
Generally, to make a poured blanket mold, the model is covered with clay and the mold shell is built over the clay-covered model, then the clay is removed and the liquid mold rubber is poured in the void left by the clay. First the model must be properly prepared (e.g., sealed and released) and mounted. Then the model is covered with plastic wrap to protect it before the clay is applied. The clay blanket is formed around the model and must fill-in any undercuts so that the mold shell cannot lock to the rubber mold. Since the shell is often made in two (or more) pieces, the clay is formed with protruding flanges, which act as parting lines for the shell. In fact, since the rubber replicates the clay blanket exactly, parting or cut lines should be delineated in the clay for transfer to the rubber. Sometimes snaps are placed along the clay blanket so that the rubber mold will snap into position in the mold shell. Cover the model with clay, then build the mold shell.
Shell (1st half) Clay Vent Vent Clay flange with groove Shell Clay plug to make pour hole in shell

The shell is made overtop of the clay usually by brushing on liquid plastic. Plastic mold shells are lightweight and durable and are typically made of Polygel Plastic or another liquid plastic (e.g., 15-6 or 1512X) thickened with an additive (e.g., Poly Fiber, see p. 61). The first section of the mold shell is built up against the clay flange. When the first section of shell is hard, the clay flange is removed, wax and then release is applied to the edge of the first shell section and the second section is built against the first section for a perfect keyed fit of the shell sections. To make the rubber mold, the clay and plastic wrap is removed from the model and then rubber is poured into the shell filling the void left behind. The rubber mold can be poured in one piece and cut with a mold key knife after curing. Or, for a two-piece mold, half of the clay is removed and rubber is poured in the void along half of the model. After the rubber cures, clay on the other half is removed, release is applied to the model and cured rubber, and liquid rubber is poured into the void along the second half of the model (see story with photos on pp. 22-23). Then pour liquid rubber into the shell.
Liquid rubber Mold strap Shell parting line

Snaps

Model

The prepared model is protected with a covering of plastic wrap and then a clay blanket (~0.5-inch thick) is built over the model. The shell is made over the clay by brushing on liquid plastic. The shell plastic is first applied to one half and cured. Then the clay flanges are removed and release agent is applied to the exposed plastic and the second half of the shell is built up to the first half.

After the clay is removed, liquid rubber is poured into the void. When making a one-piece or cut mold, all of the clay is removed and the entire space is filled with rubber. If necessary, the cured rubber is cut to remove the model.

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Mold Making Methods Brush-On Blanket Mold

A brush-on blanket mold is made first, then the shell is made over top of the cured mold for support. Some one-piece blanket molds are simply peeled off a low-relief or pyramid-shaped model (sock mold). But, often it is necessary to create a seam or cut a split in the mold to allow for removal of the model and castings. To create a parting line in the blanket mold, thin shims (e.g, aluminum flashing or stiff plastic sheet) are positioned on and securely fastened to the model. In lieu of shims, rubber can be brushed thick enough in areas so that the cured rubber can be cut to permit demolding. This technique is helpful for masters with through holes that can lock the rubber mold to the master (see pp. 20-21). If needed to prevent trapping air bubbles during casting, vents are formed in the mold by neatly fastening thin straws or rods to the model. Remember, neater fastening means less cleanup of the casting. After the model, shims and vents are coated with release, liquid rubber is brushed on. Sometimes with large models, its a good idea to create snaps or keys on the rubber mold to hold the mold in place in its shell. The shell may need to be more than one piece in order to allow removal from the rubber blanket mold. There can be no undercuts

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in the rubber mold that can lock the shell onto the rubber when there is a casting/model inside the mold (see box). The parting line for the rigid shell is defined with a clay (i.e., Poly Plasticene) flange applied over the mold. A groove or depressions should be made in the clay where it contacts the shell material to create good locking and positioning of the shell halves. The mold shell is built one section at a time against the release coated rubber mold and clay flange. When one section of the shell is complete, the clay is removed, Vaseline or butchers wax is applied to the exposed shell followed by a release agent, and the next shell section is built against the first. The two halves of the shell compress the rubber flanges along the mold opening together making a good seal so that liquid casting material cannot leak out. First, the model is prepared for making the blanket mold. Then thixotropic mold rubber is brushed on.
The model is prepared (i.e., sealed and released) and securely mounted to a base. A vent is drilled through the base to release air trapped in the model. Thin shims are placed along the model and in spaces formed under the legs and arms. The shims form a parting line in the brush-on rubber blanket mold. Once the shims are secure, the rubber is brushed on in several coats to - to -inch thick.

Dealing with Undercuts

When making a brush-on blanket Brushed-on rubber mold, all undercuts in the model must be eliminated before the mold shell is made. Typically, undercuts are filled with mold rubber or another Filled filler material -- even air. Sometimes space the filler must be compressible so that Model the mold can be removed from the model. A hollow bladder can be formed by bridging the undercut area with a piece of plastic wrap pressed into the previous layer of rubber. Then another coat of rubber can be brushed overtop of the plastic wrap. If more support is needed. the undercut can be filled with a material such as soft foam then covered with liquid rubber. In lieu of filling undercuts, a flexible mold shell can be built instead of the standard rigid mold shell. A flexible mold shell (e.g., made of Poly 74-30 rubber) can be removed from simple undercuts in the blanket mold and can sometimes alleviate the need for a multi-piece shell. Flexible 74-30 A soft, polyurethane rubber Rigid shell mother mold (e.g., Poly 74-30) can be poured over a release Brush-on coated blanket mold mold enclosed in a simple box or rigid mold. Although this option may be more expensive since it uses more rubber, it can save on labor.

Shims

Vent

After the rubber cures, the rubber-coated model is prepared for construction of the mold shell.
A clay flange is formed around the model to define Clay Flange the parting line of the rigid mold shell. Depressions are made in the clay that will form snaps in the mold shell to help properly lock the mold shell halves together. In addition, rubber Snaps snaps can be placed on the rubber mold so that the mold snaps to the mold shell. The first half of the rigid mold shell is built up to the clay flange. Then, the clay is removed and the second half of the shell is constructed. When complete, the two halves of the shell compress the rubber along the mold opening to make for a good seal along the mold opening.
Rubber-Covered Model

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Procedures - Brush-On Mold Making a Brush-On Blanket Mold with a Plastic Shell
The following example details the procedures involved in making a brushed mold. The rubber that has been chosen is Poly 74-20, a soft, stretchy, 1A:2B by weight mix ratio, polyurethane liquid mold rubber. Of course, there are many variations to this technique and several choices of rubbers. We could have chosen to make a one-piece brushed mold with shims similar to what is shown on page 19. We just as easily could have made a two-piece mold where we need no cuts to remove two separate halves of the rubber mold. This example specifically demonstrates how to create a onepiece brushed mold without shims, which requires cutting a seam in the rubber to remove the master and subsequent castings. The master, shown in Photo 1, is made of a nonporous, polyurethane plastic, EasyFlo 60. As with all sealed, non-porous masters, they must be sprayed with a silicone release such as Pol-Ease 2300 Release Agent (when using polyurethane liquid rubber) and brushed with a clean, dry brush to insure uniform distribution of the release. Care is taken not to spray too much release since brush marks can be left behind and picked up in the finished mold. Also, excess release can be accidentally pushed around when brushing liquid rubber resulting in delamination between coats or unwanted surface texture. In order to make the mixed Poly 74-20 liquid rubber thixotropic so it clings to vertical surfaces, Poly Fiber II or Cab-O-Sil must be added. In this example, Cab-O-Sil is added in small amounts (Photo 2) and the liquid is carefully folded over to wet the powder (so it doesn't come out of the cup), then it is whipped into the rubber to a creamy, uniform consistency. Only a slight amount of thickening is desired in the first coat of rubber so all surface detail is captured without trapping bubbles at the mold surface. Photo 3 shows a thin, first coat of lightly thickened Poly 74-20/Cab-O-Sil being applied with a China bristle brush. After the first layer of rubber gels enough to be undisturbed by the next coat (~45 min - faster with Part 74 Part X), a second coat of slightly thicker (a little more Cab-O-Sil used) 74-20 is brushed over the first coat (Photo 4) and allowed to gel. Before Cab-O-Sil is put into the rubber to create the mix used for the third layer, a little unthickened Poly 74-20 is poured into a PlatSil 71-20 silicone mold to make long 1-inch by 1-inch strips (Photo 5) for creating a thick rubber flange that will be placed into the freshly gelled third coat of rubber to define the location of the seam line. Notice that this model has several "through holes" (between the arms and the legs) that need to be filled completely with liquid rubber to provide a thick enough section of rubber which will be cut when cured to remove the original. This third layer is done with an even more thixotropic, non-sag mix of 74-20 and Cab-O-Sil (Photo 6). When this layer is complete, the freshly gelled strip of Poly 74-20 rubber is removed from the 71-20 silicone mold and positioned against the mold where the seam line will be cut once the mold cures (Photo 7). A final coat of lightly thickened rubber is applied after the prior coat gels to seal in the seam line strip and to make a smooth outer coating, which makes the rubber mold more attractive and fit better into its rigid support shell (Photo 8). Once the rubber mold cures (overnight, or later that day if 74 Part X accelerator is used), it is trimmed at the base and a clay wall is built up to a line that will define the parting line of the two shell sections (Photo 9). Since the shell will be rigid, there can be no undercuts that will lock it onto the rubber mold. More complicated models may require more shell sections to insure that they can be easily removed. Notice the keys/grooves in the clay wall that will insure proper registration of the shell halves. Butcher's wax is brushed over the rubber mold, allowed to dry for 10 minutes, then sprayed with a coat of Pol-Ease 2300 Release Agent. To make the shell, Poly 1512X Polyurethane Liquid Plastic is mixed together (1A:1B), then Poly Fiber thickener is added to make it thixotropic (Photo 10). Poly Fiber is added until the resulting mix clings to the side of the mixing container. The thickened 1512X is applied ~-inch thick and allowed to cure ~60 min (Photos 11). The clay wall is removed, butcher's wax and Pol-Ease 2300 applied to the other side of the mold and against the first shell section and the above procedure with 1512X is repeated. The completed shell is drilled, bolted and edges sanded for easier handling (Photo 12). When the shell is removed, a mold key knife is used to cut a notch in the rubber the length of the seam from head to toe. A sharp scalpel is then used to cut the rest of the way to the master. As the rubber is peeled open, cuts are made between the legs and arms as needed to remove the original. Cutting in these areas is done using a series of short, jagged, zig-zag cuts in order to create a series of tiny keys that keep the seam registration exact (see photo above). The finished mold and shell are now ready for production!

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Procedures - Brush-On Mold

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Procedures - Poured Blanket Mold Making a Two-Piece Poured Blanket Mold in a Plastic Shell
This page details the step-by-step production of a flexible rubber mold and plastic mother mold of the 19-inch-tall, 19th-century marble statue entitled Ice Skater by Gori Nello. To build the shell for the first half of the mold, Poly Fiber was stirred into mixed Poly 15-6 Liquid Plastic until it was the consistency of cake frosting. Then, the thickened resin was laid on the first half of the clay in a manner similar to icing a cake. [Note: When making larger shells, multiple mixes of resin and Poly Fiber can be patched against each The original marble and plaster other to cover the entire surface.] After the first half and plastic reproductions made in the Poly 74-30 blanket mold. of the shell cured (~4 hours), the aluminum shims were removed and paste wax (i.e., Butchers Wax) and then release agent were applied to the first half of the shell (Photo 4). The second half of the shell was built against the first half in the same manner (Photo 5).

Deciding on the Type of Mold

Openings under the arms and legs presented typical difficulties that influenced the selection of the type of mold to be constructed. The moldmaker decided on a blanket mold, poured in two halves into a constructed shell, because pouring yields better detail with less trapped surface bubbles. A poured mold also eliminates undercuts more easily than a brush-on mold. A double pour, with carefully selected parting lines, eliminates the need for shims (see p. 18), which would leave flashing to be chased, and cutting, which would be required with a single-pour mold and could scratch the valuable sculpture.

Selecting the Materials

Poly 74-30, a two-part, 1:1 mix polyurethane liquid rubber, was used for the mold since it is low cost, easy to mix and pour, flexible (Shore A30), and has good longevity. Poly 74-30 molds work well for casting plaster, cement, wax or resins. The mold shell was made with Poly 15-6, a 1:1 mix liquid plastic with a 5- to 7-minute working time. The plastic shell is lightweight and durable. [Note: Alternative materials for making mold shells are plaster reinforced with hemp or burlap, Polygel Plastic-75, or Poly 1512X with Poly Fiber II. The larger the shell, the more important it is to use lightweight shell materials.]

Pouring the Rubber

One-half of the plastic shell was removed along with the clay blanket beneath that half of the shell. Keys (tongue-and-groove impressions) on the second half of the clay were made in order for the two halves of the rubber mold to key or lock together (Photo 6). Vent holes were drilled in the shell with a -inch drill at each high point where air would be trapped (Photo 7). The shell was thoroughly coated with release agent, replaced and positioned for pouring the rubber. Poly 74-30 was mixed and poured into the space within the shell where the first half of the clay had been. When pouring the rubber, the model was at the bottom of the cavity so the air bubbles would rise away from the model surface. As liquid rubber appeared at the vent holes, they were plugged with plasticene clay (Photo 8). After the rubber cured overnight, the shell and clay on the second half was removed and release agent applied to the model and the face of the cured rubber parting line (Photo 9). The shell was reassembled and rubber was poured into the shell to cover the models second half. After the rubber cured, the shell halves were separated by tapping wood wedges into the seam, gradually forcing open the shell to reveal the complete mold (Photos 10 and 11).

Preparing the Statue

First, the marble statue was fastened to the base with Polypoxy Quick Stick Adhesive. The base was formica-coated particle board from a countertop sink cut-out. To protect the marble from the oils of the release agent, a thin layer of PVA (polyvinyl alcohol) solution was brushed directly on the marble. (PVA solution washes off with warm water.) After the PVA dried, a liberal coat of release agent was sprayed over the model and brushed out with a dry brush to pick up any excess and to work release into any areas missed by the spray (Photo 1).

Building the Mother Mold

Next, the statue was wrapped in plastic wrap to keep it clean (Photo 2). Then, a -inch blanket of Poly Plasticene (oil-based clay) was hand pressed onto the plastic wrap. To make the clay uniform thickness, warm Poly Plasticene (~130F) was placed between 2 equal height wood strips and rolled flat using a PVC pipe. The height of the wood strips (- to -inch) determines the thickness of the clay blanket. All undercuts were filled with Poly Plasticene so the shell could be easily removed. Shims of thin aluminum flashing were placed in the clay to create parting lines for the shell (Photo 3). These are the only shims needed with the double pour process to make this mold. A channel was built around the edge of the clay to cause the rubber mold to lock into the shell.

The Casting
Plaster was poured into the mold to clean and check the mold. Finally, release agent was applied, brushed out and the mold was properly positioned in its shell. Poly 15-3X, a mineral-filled, fast-setting polyurethane casting resin, was poured into the mold (Photo 12). The final casting was demolded in less than an hour. The excellent reproductions are shown with the original above.

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Procedures - Poured Blanket Mold

Photo 1

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Applications - Sculpture & Foundries

ill Hopen, Hopen Studio in Sutton, WV, uses Poly 74-30 thickened with Cab-O-Sil to make a brushon mold of his clay St. Joseph the Worker. Three to four layers of mixed Poly 74-30 are applied at 60- to 90minute intervals. The first layer contains little or no Cab-O-Sil so that air bubbles are minimized and fine details are reproduced. More Cab-O-Sil is added to subsequent layers for faster build up of the - to -inch mold. Twenty-four hours after the final layer, Hopen builds a rigid mold shell. The great flexibility of rubber molds allows for easy demolding of delicate wax castings. The long mold life of Poly 74-30 has enabled Hopen Studio to continue producing castings 10 years after some molds were made. These molds are made much more quickly than latex molds and at a fraction of the cost of -- Sculptor Bill Hopen silicone molds. Bill says Ive tried them Poly 74-30 Liquid Rubber thickened with Cab-O-Sil all; Polytek Mold Rubber is the best. For sculpture by Hopen call (304)765-5611.

Architectural Restoration

HR Cast Stone and GFRC of Brooklyn, NY, has restored many of the most architecturally significant buildings in New York City. Whether the medium is brownstone, limestone, terra-cotta, plaster, or stone, the artists, moldmakers, and casters at THR have reproduced and restored it to match its original beauty. Newly cast parts made from cast stone, glassfiber-reinforced concrete (GFRC), or glass-fiber-reinforced gypsum (GRG) appear original in every way. THR has used Polytek products to recreate ornamental architectural elements in theaters such as Lyric and Ed Sullivan, museums such as the Metropolitan, and hotels like the Plaza and Ansonia, as well as churches, schools, and private residences. THR prefers Polygel rubbers (see p. 36) for brush-on or sprayed molds that are created on-site from an element before it is removed from the building. For work back at the shop, THR often opts for Poly 74-45. Once a mold of the original is made, a casting is taken and the artists meticulously recreate any eroded or missing detail, based on other parts of the original still in good shape, historical photographs, etc. Once the master is completed, a mold and perfect reproductions are cast. Since many architectural features repeat on a building, a mold such as this may be used again & again -- no problem for high-performance rubbers from Polytek. 24

THR Gives New York City A Facelift with Polytek Rubbers

The Ansonia Hotel in Manhattan is just one of the strikingly ornate buildings that THR has restored. Above, Philip Gallagher of THR displays a Poly 74-45 mold that was used to recreate aging architectural brackets from a 13th-floor balcony of the Ansonia Hotel. Cast GFRC replacement brackets in the background await installation.

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Applications - Home Decor

A decorative drapery rod end was cast using EasyFlo 60 Liquid Plastic (see p. 48), a super low viscosity polyurethane product, filled with bronze powder to create this faux metal part. The two-piece poured block mold registers nicely due to keys/snaps, which keep the mold aligned properly during the casting process. A PlatSil or TinSil silicone mold could easily produce many dozen resin castings or more without the need for release agent.

A Poly 15-6 plastic column capital is demolded from a TinSil 70-11 silicone rubber mold. This rubber is very soft (Shore A10) and stretchy eliminating the need for seams in the mold to remove cast parts. The shell was made using Poly LiteCast, a very low density, pourable polyurethane plastic to reduce the weight of the shell for easier handling. The column posthole was made by inserting a plastic pipe as a plug in the 70-11 mold prior to casting.

Props, Displays & Special Effects

PlatSil Gel-10 was used by Gordon Smith of FXSmith in Toronto, Canada to make hundreds of silicone prosthetic appliances, which became the scales worn by Mystique in the blockbuster movie X-Men. Smith modified PlatSil Gel10, a versatile 1:1 mix silicone, so that it was self-sticking using Polytek's PlatSil Deadener. This allowed the scales to be removed and reapplied for each filming session without adhesives. A PlatSil 71-20 silicone rubber mold was made from a gigantic fossilized shark tooth to make a museum display item. This twopiece poured block mold is keyed extremely well with snaps and a tongue-and-groove channel to keep the flashing to a minimum. The casting was made using EasyFlo 120 with 3% PolyColor Black. The liquid plastic was poured into one half of the mold, then the mold was closed and supported between two small pieces of plywood with rubber bands, and slush-cast by hand to produce a super part in 15 minutes. Tom Kipp of Studio One/Mannetron is shown with a hollow, rotocast polyester alien that was used as a prop in the movie The Roswell Incident. The casting was made in a two-piece brushed-on Polygel 40 mold. Rotocasting equipment made by Mannetron was used to create several dozen alien figures. Polyvinyl alcohol was used as a barrier coat and the mold was washed in a warm detergent - water solution after several castings to remove styrene buildup in the mold, which could eventually damage the mold. This process helped prolong the mold life so that after several dozen castings the mold still looked like new!

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Applications - Concrete
Flexible formliners of every size and design are routinely created using Poly 74, 75 and 77-Series Polyurethane Liquid Rubbers. These Poly rubbers are tough and abrasion resistant making them ideal for the rigors of repeatedly casting large concrete parts and panels. These formliners can be made to reproduce any surface texture or design and can be bonded to plywood or attached to rigid supports for precast or castin-place applications.

Cast veneer stones are made by pouring concrete into rubber gang molds such as this one made from Poly 74-44 polyurethane rubber. Individual stones can be cast simultaneously into multicavity molds then applied to a wall to give the look and feel of real stone. Flexible formliners/molds can be made of entire wall sections for extremely large projects.

Poly 75 and 81 Series Polyurethane Liquid Rubbers are used to make concrete stamping tools and texturing skins. These stamping tools are made by pouring rubber about -inch thick onto a pattern that mimics the design that will be imprinted to the concrete. Patterns such as slate, brick, irregular flagstone or any custom design including leaves, fossils and much more turns otherwise boring, flat,concrete pathways, driveways and patios into beautifully colored and textured surfaces.

Poly 74-45, a popular 1:1 mix, polyurethane liquid rubber, was used to make a paver mold. Pavers cast from molds made from liquid rubbers have much better, life-like surface detail than those made from rigid molds owing to the fact that the liquid rubber flows readily into all available detail on the master before curing. Hundreds to thousands of concrete parts can be cast from a single mold depending upon surface texture, proper selection of mold rubber and release agent, and careful demolding.

Polygel Spray 35 was used to make a mold of this architectural element. The casting was made from glass fiber reinforced concrete (GFRC). The Polygel mold was created using a lowcost (~$4,000) machine designed to automatically meter/mix and spray the liquid rubber at a 1:1 ratio. The resulting mold is thin (~3/8-inch thick) so it is very economical and easy to peel away from complex shapes. Polygel rubber can be brushed for smaller jobs or sprayed when larger surface area molds are needed. This mold was sprayed in one continuous process, which took less than 20 minutes to complete! Polygel Spray 35 cures enough in 6-8 hours to allow a shell to be applied in the same day.

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Applications - Concrete
A decorative concrete panel was cast as part of a building restoration project by THR Cast Stone and GFRC of Brooklyn, NY. A Poly 74-45 mold is shown being carefully demolded. The thin poured blanket mold was supported by a GFRC shell and wood-framed box displayed in the background. An article in Handy Magazine described how to use Poly 7580 Liquid Rubber to make thin, low-cost texturing skins to impart a slate appearance to flat concrete. These texturing skins were made by pouring Poly 75-80 over real pieces of slate (properly sealed and released). Once the first pour gelled, a second pour was made with slightly less rubber so it didn't quite flow to the edge of the previous pour. Even less rubber was used for the third pour done to make a texturing skin that was thicker in the middle with tapered edges. This allowed the thin cured rubber mats to be overlapped at the edges to make a seamless pattern in the concrete. A thin Poly 75-80 tool is shown being removed from the freshly textured surface. With the use of concrete colors and stains the results are stunning!

Highway sound barriers are becoming more popular to keep traffic noise from residential areas. Poly 75 Series rubbers were used to make flexible formliners with wildlife images to enhance the visual appeal of the standard ribbed wall panel design. Formliner designs incorporating rock, slate, brick, fossil, wood-texture and other architectural and artistic designs are becoming more common as architects realize the endless possibilities available when flexible molds are used.

Polygel Spray 50 was sprayed onto this larger-than-life head to make a thin, yet durable, mold. With the right equipment, this type of mold can be made anywhere -- even several stories above street level.

A Poly Latex 60 mold was made to reproduce this concrete angel. The mother mold (rigid shell) was made from Poly 15-6 Liquid Plastic thickened with Poly Fiber to make it brushable. The thin blanket mold could also have been made using Polygel 35 or Polygel 40, highperformance two part brushable rubbers. Latex rubber is a onepart mold material, but 15-30 coats of rubber applied over several days are required to complete the mold. A Polygel mold can be made in a matter of hours! This Angel blanket mold is a one-piece glove mold with no seams, whereas the rigid shell is made in several sections to accommodate numerous undercuts.

If you can pour concrete, you can pour liquid rubber!

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Mold Making Methods

Applications - Prototyping & Model Making Prototype Parts of All Kinds Made with Polytek Liquid Rubbers & Plastics
Larami Limited, headquartered in Mt. Laurel, NJ, is the originator and manufacturer of the internationally-recognized Super Soaker toy water guns. With engineering and prototype model development facilities in Whitehouse Station, NJ, Larami Limited has been using Polyteks mold rubbers, such as PlatSil RTV Silicones, and casting plastics, such as Poly 15-3X, Poly 1512 and Poly-Optic 1410, very successfully to create their new products. Producing the Prototype Many different techniques involving numerous Polytek products are employed in the production of a unique model or prototype part such as the Super Soaker. Master models can be carved from wood, sculpted from clay, machined from polyurethane board, wood or plaster using CNC equipment, or created from a liquid photopolymer using a stereolithography process. As with any mold making process, it is important to determine the most appropriate combination of mold making and casting materials for the project at hand. If wax castings are to be made (say for a lost wax process as is used for making many metal prototype parts), then a polyurethane mold rubber such as Poly 74-30 or Poly 74-45 (see p. 34) may be the best choice as they are most cost-effective and release waxes nicely. Many times plastic parts are the desired end result, as in the case of a Super Soaker. PlatSil and TinSil RTV Silicone Rubbers (see pp. 40-45) are the best choice for casting polyurethane plastic prototypes. These highperformance silicone rubbers offer the best mold life and resistance to damage from repeated casting with chemically aggressive liquid polyurethane resins. TinSil 70-25 and 70-39 are popular silicone rubbers for modelmakers since they are lower-cost, tincatalyzed systems and have hardnesses that makes difficult parts easy to demold. When using any tin-catalyzed silicone rubber, be sure to perform a test cure to insure the alcohol released during the rubbers cure does not interfere with the cure of the polyurethane plastic. If alcohol on the mold surface poses a problem, heating the mold to 200F for several hours can assist alcohol removal. Any PlatSil rubbers can be used for casting polyurethane plastics. PlatSil 71-20 is an easy 1:1 mix, Shore A20 rubber with a super low viscosity and 4-hour demold. For applications requiring firmer rubber, PlatSil 71-35, 73-45, or 73-60 provide excellent tear and suitable hardnesses. When pouring any one of the TinSil or PlatSil rubbers over a model, PolEase 2350 Release Agent (non-silicone) should be evaluated as a release. Poly Plastics Have Thermoplastic Feel The Poly 15-Series products (see p. 49) offer many types and speeds of cure for almost every application. Poly 1512 and 1512X are most popular for prototypers interested in a tough, high-performance product with a thermoplastic feel. It has a 1:1 mix, can be easily colored with PolyColors, has low viscosity, a fast (5 min) or slow (20 min) potlife, and very impressive physical properties when cured. It is non-brittle in thin sections and has a high tensile strength. It can be sanded, carved, machined or painted as needed. Other 15-Series plastics can be used for lower (Poly LiteCast, page 54) or higher density (Poly 15-3X) parts. Poly 15-8 is also available for modelmakers interested in making heat-resistant tools for vacuumforming applications. For rapid-casting applications of complex parts requiring a resin

Larami Ltd., originator of the Super Soaker, uses Polyteks rubber and plastic products to make molds and castings for various prototyping projects. with a super-low mixed viscosity, try EasyFlo 60 Liquid Plastic (see p. 48). Rotational Casting An additional use of Polytek fast casting plastics at Larami was to rotationally cast the large pressure tank prototype for the Super Soaker squirt gun by rotating the hollow tank mold with a small amount of a Poly Plastic such as Poly 15-3X coating all surfaces as it set. Poly 15-3X sets in about 15 minutes at room temperature, but the silicone rubber mold was heated to hasten the set and demolding time of the Poly 15-3X resin. All Poly 15 Series resins can also be accelerated with a few drops of Poly 15 Part X Accelerator. See pages 46-56 for more information on Polyteks Liquid Plastics and page 64 for more on rotocasting. Water-Clear Poly-Optic 1410 Another Polytek polyurethane plastic used by Larami is Poly-Optic 1410, a water-clear, low viscosity resin, which can be used for transparent parts such as face shields, toy-auto windshields, windows, headlights and eyes.

PlatSil 71 and 73 Series mold rubbers are widely used for model making and prototyping. This two-piece block mold made of PlatSil 71-35 is used to reproduce a thin-walled car model. Prototypers cast dimensionally accurate parts fast using EasyFlo 60 Liquid Plastic (see p. 48).

Pressure casting can help prototypes and model makers create perfect, bubble-free castings. See page 16.

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Mold Making Methods

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Mold Making Methods 29

Applications - Cast Polyester/Fiberglass Parts

Restoration of the Widener Building in Philadelphia began in the summer of 1990, by Russ Veder, an expert in architectural restoration and principal of American Architectural Art. This project required making detailed flexible rubber molds of the building's ornate Corinthian column capitals, which measure 8 feet by 7 feet with deep 24-inch undercuts. Russ, with subcontractor, Edon Corp., resculpted a fiberglass duplicate of the aged capital to bring it back to its original design. The duplicate was used as a working model to make a Polygel mold that ultimately produced the 10 fiberglass capitals needed for the restoration. Fabric reinforcement was pressed into the wet rubber where needed and soft, flexible foam was pressed into the undercuts to allow the shell to be removed more easily. A final coat of Brush-On Polygel Molds Used to Cast Polyester/Fiberglass Capitals Polygel 40 was used to cover the fabric and foam. A fiberglass shell was made the following day. Cast Russ Veder, of American Architectural Art, chose Polygel rubbers because fiberglass/ polyester resin parts were sprayed into the of their ability to be brushed on easily and capture incredible detail. Edon moldmakers Matt Axel and Bob Mathias agreed, "Polygel was the best mold Polygel mold that was coated with a polyvinyl rubber we ever used. After casting 10 large fiberglass parts, the mold was alcohol (PVA) barrier coat to protect the mold from in such good condition, we could have made 50 more." the harsh effects of the polyester resin.

Tony Lorino, Capitol Displays of Nashville, TN, uses Poly Latex 60 molds to produce polyester and fiberglass copies of original sculpted models. Poly Latex 60 is the rubber of choice because of its durability and ease of application. Being a single component material, Poly Latex 60 is brushed on without the limitation of a pot life. Ten to twenty coats are applied, two per day, to build up proper mold thickness. Gauze is often incorporated into the latex to lend additional strength to large molds. Lorino then builds a rigid polyester and fiberglass mold shell over the latex mold to maintain the shape of the mold during casting. Poly 15-6 and Poly Fiber, or Polygel Plastic-75 should also be considered for this application. The end result is a lightweight, high tear strength mold with good resistance to the swelling caused by polyester resin. Poly Latex 60 molds allow Capitol Displays to produce detailed parts with undercuts that would be impossible with rigid molds.

Poly Latex for Polyester Fiberglass Parts -- Capitol Displays

Poly Latex 60 was brushed on a sculpted resin model to produce this large blanket mold for a decorative architectural part.

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Mold Making Methods

Mold Making Methods

Applications - Foam Parts & Shells

Poly 15-3X, 1:1 mix polyurethane plastic, was rotocast to create a thin, lightweight, hollow casting. After the 15-3X gelled in ~5 minutes, Poly 15-6 polyurethane plastic with 3% (by weight) Part 15F Foamer was poured into the hollow 15-3X shell while still in the mold. The 15-6/Part F open-cell foam expanded to fill the cavity giving the hollow casting support without adding much cost or weight. PolyFoam R-5, a 1:1 by volume rigid foam, was used to create a very lightweight mold shell to support this brushed blanket mold of Poly 74-29 polyurethane rubber. The shell was made by pouring liquid PolyFoam R-5 into an unsealed wooden box built around the cured rubber mold that was covered with butcher's wax for release. When the foam expanded, it adhered to the box and conformed to the shape of the rubber mold. A little foam goes a long way! PolyFoam R-8, a 1:1 by volume, closed-cell foam, makes strong, lightweight castings quickly. PolyFoam is mixed and poured into a TinSil or PlatSil silicone rubber mold, which is covered with a lid to pack the foam to a higher density for good mold fill, thicker skin, and better surface detail. About 20 minutes later, parts such as this plaque or pot can be removed from the mold. A barrier coat, such as Barrier PF, can be applied to the mold to prolong mold life and provide primed/painted parts upon demold. PolyFoam R-5 and R-8 can be used to easily create parts such as these plaques. Since the foams are selfskinning, the plaques have all the detail of the original.

Hollow Lightweight Castings

Poly 1512X, a 1:1 mix, pourable, high strength, polyurethane liquid plastic was mixed with PolyFiber thickener to turn the pourable plastic into a non-sag, thixotropic mix that was laid up by hand into a Polygel mold of a boulder. A thin face coat followed by a thicker backup coat were applied to create a total thickness of approximately inch. Very little material was needed, so the resulting casting was lightweight and low cost. A similar hollow casting could have been made using polyester resin and fiberglass or glass-fiber reinforced concrete. This 10-inch tall head was rotocast using just a few pounds of EasyFlo 120, a 1:1 by volume mix, polyurethane plastic that is designed for rotocasting (see equipment on p. 63) and slush casting, which is done by hand. If poured solid, this casting would weigh and cost much, much more. EasyFlo 120 captures all the detail without thin spots or bubbles.

A poured blanket mold made of Poly 74-20 polyurethane rubber was made from a chainsaw-carved wooden bear to create lightweight duplicates. Notice the thickened seam line in the back of the mold that was cut with a mold key knife to permit easy demolding and minimal seam cleanup. Since this mold is larger, "snaps" or "buttons" were made in the clay blanket which ultimately became part of the rubber mold so the mold would not flop away from the shell while being rotated in the rotocasting machine.

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Mold Making Methods

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Mold Making Methods 31

Applications - Statuary & Figurines

This 12-inch tall sculpture of a mother and child was created by Mary Smith of Leesport, PA, and was molded at a Polytek Seminar & Workshop using PlatSil 71-10 Liquid Silicone Rubber. The sculpture was disassembled into two pieces so that the child could be molded separately from the mother. The cold-cast bronze figurines were made by slushing a thin coating of Poly 1512X mixed with bronze powder around the surface of the mold until it gelled. Then a dense, low-cost polyurethane plastic (Poly 15-3X) was used as a backfill to simulate the weight of a real bronze casting. The resulting figurines were glued together using EpoxyBond adhesive and felt was applied to the bottom. Faux bronze at its best! These frogs were cast in a TinSil 70-25 silicone mold. Each cold cast bronze was made from EasyFlo 60 Plastic with bronze (mix ratio 1A:1B:2 bronze, by volume) and finished with a different patina for a unique look.

A poured blanket mold was made using PlatSil 71-20 Liquid Silicone Rubber, a unique, 1:1 mix, 4-hour-cure system, which can be used to cast any medium. This gargoyle could now be cast in plaster, concrete or any pourable plastic using this PlatSil mold. This blanket mold was poured in a single piece, then cut, using a mold key knife, up both sides to create a mold which opens like a book.

& More!
The use of Polyteks liquid mold rubbers and casting plastics is not just limited to the applications described on the past several pages! Candle makers Soap manufacturers Jewelers Taxidermists Forensic scientists Hobbyists of all kinds Inventors & many others Use Polytek products to make their creations.

If you have an application you dont see here, call Polytek Customer Service for assistance. The use of Polytek materials is limited only by the imagination -- may yours be limitless.

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Polyurethane RTV Mold Rubbers

Polyurethane RTV Liquid Mold Rubbers

Polyurethane Mold Rubber Polytek offers several Polyurethane RTV Liquid Mold Rubbers each formulated to meet various customer applications. Polyteks polyurethane mold rubbers consist of a Part A and a Part B that, after mixing, cure at room temperature to flexible, high-strength, mold rubbers. Polyurethane rubbers make durable, easy releasing molds for casting plasters and waxes without release agents, but when used with proper release agents are also excellent for casting concrete, epoxy, polyester, urethane and acrylic. For many Polytek polyurethane mold rubbers, the last two digits in the product name indicate the approximate Shore A hardness of the cured rubber. Polytek polyurethane mold rubbers range in hardness from a very soft A20 to a very firm D45. MODEL PREPARATION Porous models, such as wood, plaster, stone, pottery or masonry, must be sealed, then coated with a release agent. Multiple coats of paste wax dried and buffed will seal most surfaces. Potters soap can be used as a sealer for plaster. Lacquer, paint, PVA, PolyCoat and Pol-Ease 2350 also work well as sealers for many surfaces. Models made of sulfur-containing modeling clay (i.e., Roma Plastilina) should be sealed with shellac. [CAUTION: When shellac is used as the sealer, it must be thoroughly coated with release agent because polyurethane rubbers bond tenaciously to shellac. In fact, uncoated shellac may be used to bond polyurethanes to certain surfaces (i.e., plaster).] Non-porous models (i.e., metals, plasticene, wax, glazed ceramics, fiberglass, and polyurethanes) and sealed porous models should be coated with a release agent such as Pol-Ease 2300. If there is any question about the compatibility between the liquid mold rubber and the prepared model surface, perform a test cure on an identical surface to determine that complete curing and good release is obtained. Porous models must be vented from beneath to prevent trapped air from forming bubbles in the rubber (see p. 12). MIXING AND CURING Before mixing rubber, be sure that both Parts A and B are at room temperature and that all tools and models are ready to go! Check product labels or technical bulletins to determine working time for the product -- some products set fast -- meaning that you must work quickly. Many Polyurethane Part Bs require stirring before use. If there is a Stir Before Use label on the container -- be sure to do so. Mix Ratios Vary! Check the mix ratios for the specific product you are using. For polyurethane rubbers, most mix ratios are expressed by weight. Carefully weigh Parts A and B in proper ratio. [Note: Polygel products can be mixed 1:1 by weight or volume. See p. 36.] Weigh Part B (usually the lower viscosity component) into a clean metal or plastic mixing container. Then weigh the appro32

POLYURETHANE MOLD RUBBERS: AT A GLANCE

Poly 74 & 75 Series - Flexible, high-strength mold rubbers for making tough, durable molds. Polyteks easiestto-use and best-selling mold rubbers! Polygel Series - Thicken immediately upon mixing components making these products exceptional for making brush-on or sprayed blanket molds. Poly 77 Series - High elongation mold rubber for maximum mold life in high volume applications. Poly 81 Series - Firm rubber for making durable molds, forms or industrial parts. Poly 72-40 Series- Flexible rubber that performs well for casting wax and plaster. Poly GlassRub- Clear, flexible rubber for making cut molds or casting clear or colored art/decor objects. priate amount of Part A into the same container. Mix thoroughly. Hand mixing with a Poly Paddle (see p. 62) is best to avoid mixing air into the rubber. While mixing, scrape the sides and bottom several times to insure thorough mixing. Pour the rubber as soon after mixing as possible for best flow and air bubble release. Vacuum degassing or pressure curing helps to provide bubble free molds, but is usually not necessary. Allow the rubber to cure at room temperature, 77F (25C). Heat accelerates the cure - low temperatures slow the cure. Avoid curing in areas where the temperature is below 60F (15C). Check product labels or technical bulletins to determine appropriate cure times. For most polyurethane products, final cure properties are obtained in about seven days, but most molds may be used with care after curing for 24 to 48 hours. USING THE MOLD Usually no release agent is necessary when casting plaster or molten wax in polyurethane molds. When casting with plaster, sponge, dip, or spray the mold with Pol-Ease Mold Rinse and then pour plaster on the wet mold to reduce air bubbles in the plaster and aid release. When casting resin, spray the mold with Pol-Ease 2300 Release Agent. For casting concrete, use an appropriate form release such as Pol-Ease 2650 or 2601 Release Agent. Exposure to solvent-containing form releases should be kept to a minimum to reduce likelihood of mold distortion due to shrinkage or swelling. After repeated casting with certain resins, plaster and concrete, molds may shrink or swell since these materials can either extract oils from the mold or force chemicals into the rubber matrix. The proper selection of release agent and/or barrier coat can minimize this effect. If shrinkage becomes evident, a light application of
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Polyurethane RTV Mold Rubbers

Pol-Ease Mold Dressing can help to restore the mold to its original dimensions. For more information on the use of Pol-Ease Mold Dressing, call Polytek Customer Service. ADDITIVES Polytek offers various additives that can be used to vary the properties of the cured and uncured polyurethanes. Softener - For the Poly 74, 75 and 77 Series RTV Liquid Mold Rubbers, add Poly 74/75 Part C Softener for a lower viscosity mix and a softer cured rubber. Poly 74/75 Part C Softener may be added to most other Polytek polyurethane mold rubbers except Poly 72-40. Accelerator - For Poly 74, 75 and 77 Series RTV Liquid Mold Rubbers, Poly 74/75 Part X can be added to accelerate the cure. Poly 74/75 Part X may accelerate other Polytek polyurethane mold rubbers. Test on a small scale first. Thickeners - Poly Fiber II is a fine fiber that is used to thicken polyurethane rubbers and plastics to a thixotropic consistency for brushed rubber molds and plastic shells. Cab-OSil Fumed Silica is both a thickener and thixotropic agent. Add Poly Fiber II or Cab-O-Sil to mixed Parts A and B in order to form a gel appropriate for application by brush or trowel. Cab-O-Sil is only appropriate for use with certain liquid mold rubber products. UV Stabilizer - Poly UV Additive can be added to mixed Parts A and B to improve UV resistance of cured Polytek mold rubbers. At 0.5% of the total weight of the liquid mix, UV Additive reduces characteristic surface degradation caused by sunlight and other UV sources. Colors - Polyurethanes can be tinted to various colors by adding small amounts of PolyColors (see p. 61).

Molds and castings made from Polytek polyurethane products.

ADDITIVES & ACCESSORIES

Poly 74 Part C Softener 1 pint (1 lb), 1 gal (8 lb), 5 gal (40 lb) Poly 74/75 Part X Accelerator 1 pint (1 lb), 1 gal (8 lb) Pol-Ease 2300 Release Agent 12-oz. can, case of 12 cans Pol-Ease 2450 Release Agent 1 qt (2 lb), 5 gal (40 lb) Pol-Ease 2500 Release Agent 12-oz. can, case of 12 cans Pol-Ease 2601 Release Agent 1 qt (2 lb), 5 gal (40 lb), Drum (450 lb) Pol-Ease 2650 Release Agent 1 qt (1.5 lb), 5 gal (35 lb), Drum (375 lb) Pol-Ease Mold Rinse or Mold Dressing 5 gal (40 lb) Poly PVA Solution (Green or Clear) 1 qt (2 lb), 5 gal (40 lb) PolyCoat 1 qt (1.5 lb), 1 gal Poly Purge Aerosol Dry Gas 10-oz can, Case of 12 cans Cab-O-Sil/Fumed Silica 5 gal, 1 bag (10 lb) Poly Fiber II 5-gal pail (~3 lb), bag (10 lb)

To learn more about additives, refer to product technical bulletins or call Polytek Customer Service. Additives and accessories for polyurethane mold rubbers are listed in the box to the right. CLEAN UP Tools should be wiped clean before the rubber cures. Denatured ethanol is a good cleaning solvent, but it must be handled with extreme caution owing to its flammability and health hazards. Work surfaces can be waxed or coated with Pol-Ease 2300 Release Agent so cured rubber can be removed. SAFETY Before use, read product labels and Material Safety Data Sheets. Follow safety precautions and directions. Contact with uncured products may cause eye, skin and/or respiratory irritation and dermal and/or respiratory sensitization. Avoid contact with skin and eyes. If skin contact occurs, remove with waterless hand cleaner or alcohol then soap and water. In case of eye contact, flush with water for 15 minutes and call a physician. Use only with adequate ventilation. Do not use polyurethane products where food or body contact may occur. Polyurethanes burn readily when ignited. STORAGE LIFE At least six months in unopened containers stored at room temperature (60-90F). Parts A and B react with atmospheric moisture
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and, therefore, should be used up as soon as possible after opening. After opening, spray Poly Purge Dry Gas Blanket into containers before resealing to displace moist air and extend storage life. Polyurethane rubber molds can last many years if stored in their proper shape in a cool, dry location out of direct sunlight. 33

Polyurethane Mold Rubber

Polyurethane RTV Mold Rubbers

Poly 74 and 75 Series RTV Liquid Rubbers

DESCRIPTION: Poly 74 and 75 Series Liquid Rubbers consist of Part A and Part B that, after mixing, cure overnight at room temperature to flexible, high-strength, mold rubbers. Poly 74 and 75 Series Rubbers make durable, easy releasing molds for casting plasters and waxes without release agents, but when used with proper release agents are also excellent for casting concrete, epoxy, polyester, urethane and acrylic. MODEL PREPARATION: See p. 32. MIXING AND CURING: See p. 32. USING THE MOLD: See p. 32. ADDITIVES: For general guidelines see p. 33. Softener - For the Poly 74 and 75 Series RTV Liquid Mold Rubbers, Poly 74/75 Part C Softener can be added to the uncured products for a lower viscosity mix and a softer cured rubber. When Part C is used, cure time is longer and there is some loss of strength in the rubber and increased tendency to shrink after repeated castings. To soften Poly 74-30 to a Shore A15, mix 1A:1B:1C, by weight. The quantity of Part C required to soften other products varies and should be determined through experimentation. Accelerator - For the Poly 74 and 75 Series RTV Liquid Mold Rubbers, Poly 74/75 Part X can be added to accelerate the cure. Part X is most useful when making brush-on molds with 74Series rubbers to decrease the time needed between coats. By adding 3% Part X (by weight of the total mix) to 74-30 or 74-29,

FEATURES
Easy-to-use formulations Flexible, strong mold rubbers Reproduce fine details Make tough, long-lasting molds and parts

Polyurethane Mold Rubber

the working time is reduced to approximately 8 minutes -- in the time it takes to mix the next batch, the previous brushed layer gels enough to apply the next coat. Demolding is possible in as little as 4 hours after the final layer is applied. Rapid curing with Part X allows a firm, yet flexible shell or mother mold to be made in the same day. For example, by adding 1% Part X (by weight of total mix) to Poly 75-80, the working time is reduced to approximately 10 minutes and demolding is possible in as little as 6 hours. Exercise caution when using Part X for poured molds since the rapid onset of gelling may trap air bubbles on or near the surface of the master. Poly 74/75 Part X affects each product differently. Before use, testing to determine the best amount of Part X to use is advised. CLEAN UP: See p. 33. SAFETY: See p. 33.

POLY 74 SERIES PHYSICAL PROPERTIES

74-20 Mix Ratio, By Weight Hardness, Shore A Pour Time (min) Cured Color* Mixed Viscosity (cP) Specific Volume (in /lb)
3

74-29 (74-29 White) 1A:1B 30 30

74-30
(74-30 Clear)

74-40 2A:1B 40 20 Varies 3,400 27.5

74-44 2A:1B 45 20 Gray 3,500 27.5

74-45 1A:1B 45 30 Yellow 2,500 27.5

74-55 4A:1B 55 15 Clr Yellow 4,000 27.5

1A:2B 20 30 Yellow 800 27.5

1A:1B 30 30

Black Varies (White) (Clear/Amber) 2,800 27.5 2,000 27.5

POLY 75 SERIES PHYSICAL PROPERTIES

75-59 Mix Ratio, By Weight Hardness, Shore A Pour Time (min) Cured Color Mixed Viscosity (cP) Specific Volume, in /lb
3

75-60 1A:1B 60 10 Amber 1,200 27

75-65 1A:1B 65 35 Yellow/Amber 3,000 27

75-70 1A:1B 70 40 Gray 3000 27

75-75 2A:1B 75 20 Amber 4,000 26

75-79 2A:1B 80 20 Yellow 2,000 26

75-80 2A:1B 80 45 Yellow/Amber 5,000 26

75-90 2A:1B 90 10-15 Tan/Brown 6,000 26

1A:1B 60 10 Amber 2,500 27

* Some Part Bs darken with age, but cured rubber properties are not affected.

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Polyurethane RTV Mold Rubbers

Poly 74-20 offers the most remarkable combination of tear strength and softness. With tear strength similar to harder rubbers, Poly 74-20 pulls away from detail and undercuts with no trouble at all. Poly 74-20 is great for casting concrete, plaster wax and resins.

Moldmaker Chan Oeur (looking at camera) demolds a Poly 74-30 brushed mold from one of six panels created by artist Kate Burke for the Minnesota Veterans Home. They sprayed the model with Pol-Ease 2300 Release Agent, so the separation was perfectly clean and trouble-free.

A satisfied seminar attendee displays her cold cast bronze pot demolded from a twopiece, poured block mold made from Poly 74-20. The keys, which register the top and bottom halves of the mold, worked perfectly to create a thin, uniform wall thickness on the cast part.

74- & 75-Series Packaging Product (Mix Ratio) Unit Weight (lb)
6 24 120 1,350 4 16 80 900 6 24 120 675 1,350 5 20 40 100 562.5

Unit Components
Part A (lb) 2.0 8.0 40.0 450 2.0 8.0 40.0 450 4.0 16.0 80.0 450 900 4.0 16.0 32.0 80.0 450 Part B (lb) 4.0 16.0 80.0 900 2.0 8.0 40.0 450 2.0 8.0 40.0 225 450 1.0 4.0 8.0 20.0 112.5 Part A (volume) 1 qt 1 gal 5 gal 55 gal 1 qt 1 gal 5 gal 55 gal 2 x 1 qt 2 x 1 gal 2 x 5 gal 55 gal 2 x 55 gal 2 x 1 qt 2 x 1 gal 5 gal 2 x 5 gal 55 gal Part B (volume) 2 x 1 qt 2 x 1 gal 2 x 5 gal
22 x 5 gal/2 x 55 gal

Poly 74-20 Mix Ratio: 1A:2B

Poly 74-29, 74-30, 74-30 Clear, 74-45 Poly 75-59, 75-60, 75-70 Mix Ratio: 1A:1B Poly 74-40, 74-44 Poly 75-75, 75-79, 75-80, 75-90 Mix Ratio: 2A:1B

1 qt 1 gal 5 gal 55 gal/11 x 5 gal 1 qt 1 gal 5 gal 6 x 5 gal 55 gal 1 pt 2 x 1 qt 1 gal 5 gal 3 x 5 gal

Poly 74-55 Mix Ratio: 4A:1B

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Polyurethane Mold Rubber

Poly 74-40 was used to make a poured blanket mold of this shelf bracket. The bracket was rotocast using Poly 15-3X polyurethane to make a hollow part that was then backfilled with Poly 15-6 and Part 15F Foamer to give it strength while keeping it lightweight and low cost.

Polyurethane RTV Mold Rubbers

Polygel Brushable/Sprayable Mold Rubber

U.S. Patent # 5,128,433 USES: Polygel Mold Rubbers are without equal for brushed or sprayed blanket molds. Polygel Plastics produce strong, lightweight mold shells (see p. 46). Polygel products are ideal for molds and shells built up with a brush or spatula on vertical or overhead surfaces. Evaluate Polygel Mold Rubbers for casting plaster, cement and waxes, as well as for limited casting with polyester, epoxy and polyurethane resins. Sprayable Polygel products are ideal for large surface area applications where brushing may be impractical. Polygel products bond well to many surfaces and should be evaluated as adhesives and sealants. DESCRIPTION: Polygel products consist of liquid Parts A and B, that after mixing 1:1 by weight or volume, immediately selfthicken to a brushable or trowellable consistency. As the liquid components of Polygel Mold Rubbers are mixed together, the product changes color and thickens to a buttery, non-sag paste with a working time of 1 to 20 minutes (depending on the specific Polygel product used). A mold can be built up in 2 to 3 coats, applied about 1 hour apart. Polygel Spray 35, Spray 50 and Quick Spray 50 can be sprayed continuously until the desired mold thickness is achieved. Polygel rubbers cure overnight at room temperature to flexible, tough rubbers. Polygel Spray 35 and Quick Spray 50 cure in 4-6 hours. MODEL PREPARATION: See p. 32. MIXING AND CURING: See p. 32.

FEATURES
Easy -- 1:1 mix by weight or volume Excellent for brush-on and spray applications Fast -- one-day molds Tough and strong Color-coded mix indication Molds have long library life Good flow into fine detail Good dimensional stability

Polyurethane Mold Rubber

BRUSH-ON MOLDS WITH POLYGEL RUBBER: When brushing Polygel rubber, allow the first coat to gel enough so that the second coat will not disturb it (usually about 1 hour is adequate, 30 minutes for Polygel 35), then apply a second coat being careful to cover any thin spots in the first coat. Do not allow prior layers to cure completely before applying subsequent coats. Sprayed molds should be made in one continuous application without the need for individual layers. Ideally, a blanket mold should be at least 1/8-inch thick but not more than 3/8-inch, since too thick a layer of rubber causes difficulty turning a mold back on itself during demolding. Allow to cure at room temperature prior to demolding or building the mold shell. Strength continues to develop for several days. REINFORCING BRUSH-ON MOLDS: Rubber molds can be reinforced with Tietex Fabric (see Accessories), which is strong and wets out better than other fabrics. Tietex can be laminated at the top of a seam or strips can be laid around the perimeter of a mold to prevent tearing. The fabric can be embedded in the second or third coat of rubber while tacky and covered with a subsequent coat, which should be as fluid as possible for best penetra-

Polygel Product Options

Polygel 35 - Softest, most elastic, brushable Polygel rubber. Cures to Shore A35 hardness in 4-6 hours. Polygel Spray 35 - Sprayable version of Polygel 35 designed for use with meter-mix spray equipment. Polygel 40 - The lowest viscosity mix for best air bubble release and easiest brushing. Cures to a Shore A40 hardness. Polygel 50 - A thicker mix that cures to a tough Shore A50 hardness. Polygel 50 is a great adhesive for repairing polyurethane molds and bonding molds to backing material such as plywood. Polygel Spray 50 - Designed for spray mold applications using meter-mix spray equipment. Polygel Quick Spray 50 - A fast, sprayable mold rubber with a 1-minute working time and a 4 to 6-hour cure. Polygel Plastic-75 - See p. 55. Polygel Shell - See p. 55.

Polygel Mold Rubbers are specifically designed for brush-on and spray application. After Parts A+B are mixed, they form a thixotropic gel that clings to vertical and overhang surfaces after application. (610)559-8620 (800)858-5990

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Polyurethane RTV Mold Rubbers

Polygel Spray 50 is applied to a monumental sculpture with the VS-3000 Polygel Sprayer (see p. 64). Using the sprayer, the entire mold was made in a continuous sprayed piece. The gel emitting from the sprayer is non-sag and, therefore, stays where it is applied, but can be moved around with a brush if necessary.

Using Polygel Spray 50 a mold was made of this this large cornice bracket.

tion of the cloth. If the fabric is too close to the model surface, the weave pattern may show through to the face of the mold. NOTE ON LAYERING DIFFERENT POLYGEL RUBBERS: Typically, brush-on molds should be completed with one rubber. For example, if the face coat is brushed with Polygel 40, then all subsequent coats should be with Polygel 40. In some cases, the initial coat can be brushed with lower viscosity Polygel 35 or 40 for better detail and the second (usually final) coat with thicker Polygel 50 to speed the mold making process. This technique is acceptable for molds that do not require long-term storage or use. When layering different products, oils can transfer from one rubber to another causing warping or curling of the mold. In extreme cases, a mold can distort enough that it will not fit properly into its shell. THICKER MIXES FOR FILLING UNDERCUTS: Polygel Mold Rubbers can be made even thicker by stirring Poly Fiber II or Cab-O-Sil into the mixed Parts A and B. USING THE MOLD: See p. 32. If a Polygel rubber mold is to be turned inside out like a sock, the outside surface must be lubricated with soapy water or petroleum jelly so that it slides over itself easily. The shell or mother mold can be made of Polygel Plastics, plaster, polyester resin and fiberglass, or Poly 15-6 or 1512X resin filled with Poly Fiber or fiberglass (see p. 61). If the shell is built with Polygel Plastics or other resin, the rubber must be thoroughly coated with paste wax then Pol-Ease 2300 Release Agent to prevent the plastic from sticking to the rubber. A plaster shell must be sealed with potters soap, shellac, lacquer or wax to prevent mold distortion during storage or use. CLEAN UP: See p. 33. SAFETY: See p. 33. When spraying Polygel products, use adequate ventilation and personal protective equipment (i.e., respirators, gloves, coveralls).

This Polygel mold was used to rotocast hollow plaster columns used routinely for home and office decor.

POLYGEL MOLD RUBBER PACKAGING Products

Polygel 35 Polygel 40 Polygel 50 Polygel Spray 35 Polygel Spray 50 Polygel Quick Spray 50

Unit Weight (A+B) 4 16 80 900 lb lb lb lb

80 lb 900 lb 37

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Polyurethane Mold Rubber

A large, flexible rubber dome mold was made quickly using Polygel Spray 50 for the restoration of the St. Joseph County Courthouse in Southbend, IN.

Polyurethane RTV Mold Rubbers

Poly 77 Series RTV Liquid Rubbers

DESCRIPTION: Poly 77 Series RTV Liquid Rubbers consist of a liquid Part A and Part B that, after mixing, cure at room temperature to economical, flexible mold rubbers. Consider these products for casting plasters, cements and waxes. Resins can also be cast with proper release agents. The Poly 77 Series has been formulated to provide excellent abrasion and tear resistance for maximum mold life and performance. The high elongation characteristic of these rubbers enables easier demolding and reduces mold damage when used in demanding casting applications. MODEL PREPARATION: See p. 32. MIXING AND CURING: See p. 32. USING THE MOLD: See p. 32. CLEAN UP & SAFETY: See p. 33. PHYSICAL PROPERTIES
Mix Ratio, By Weight Hardness, Shore A Pour Time(min) Color Mixed Viscosity (cP) Specific Volume (in3/lb) 77-50 1A:1B 50 15 Tan 1,200 27.5 77-65 1A:1B 65 15 Tan 1,600 27.5

FEATURES
High-performance, high-elongation rubbers Hardnesses ranging from Shore A50 to A65 Easy-to-use formulations with 1:1 mix ratios Easy demolding without damaging molds Make tough, long-lasting molds

Polyurethane Mold Rubber

PACKAGING Poly 77-50 and Poly 77-65

Mix Ratio: 1A:1B (By Weight) Unit Weight (lb) Part A (lb) 4.0 16.0 80.0 900 2.0 8.0 40.0 450 Unit Components Part B (lb) 2.0 8.0 40.0 450 Part A
(Volume)

Part B
(Volume)

1 qt 1 gal 5 gal 55 gal

1 qt 1 gal 5 gal 55 gal

Poly 81 Series RTV Liquid Rubbers

DESCRIPTION: Use Poly 81 Series rubbers to make firm molds, mold facings, stamping tools, industrial parts, rollers, gaskets, mold shells, bumpers or pads. Poly 81 Series rubbers consist of liquid Part A and Part B that, after mixing, cure at room temperature to tough, durable rubbers. They offer low sensitivity to moisture, and low viscosity for easy vacuuming, if necessary. MODEL PREPARATION: See p. 32. MIXING AND CURING: See p. 32. Parts A and B are clear liquids. The color of Part B may vary, but it has no effect on cured rubber properties. USING THE MOLD: See p. 32. CLEAN UP & SAFETY: See p. 33. PHYSICAL PROPERTIES
81-90 Mix Ratio, By Weight Hardness (Shore A/D) Pour Time (min) Demold Time (hr) Color Mixed Viscosity (cP) Specific Volume (in3/lb) 100A:40B A90 23 16 Yellow 2,000 26.6 81-D45 100A:20B D45 19 16 Varies 1,600 26.4 Product (Mix Ratio)

FEATURES
Firm rubbers ranging from Shore A90 to D45 Easy-to-use formulations Reproduce fine details Make tough, long-lasting molds, tools and parts

PACKAGING Poly 81-Series

Unit Weight (lb) 11.2 56.0 280 630 9.6 48.0 192 540 Component Weight (lb) Part A 8.0 40.0 200 450 8.0 40.0 160 450 Part B 3.2 16.0 80.0 180 1.6 8.0 32.0 90.0

Poly 81-90 (100A:40B)

Poly 81-D45 (100A:20B)

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Polyurethane RTV Mold Rubbers

Poly 72-40 Series RTV Liquid Rubbers

DESCRIPTION: Poly 72-40 systems consist of liquid Part A and Part B that, after mixing in correct ratio, cure at room temperature to versatile mold rubbers. They may be poured or thickened and applied by trowel or brush, to make flexible molds. These molds are typically used for making wax castings in foundry applications. MODEL PREPARATION: See p. 32. CAUTION: Poly 72-40 systems may be subject to cure inhibition by certain contaminants and may stick to some surfaces. See Technical Bulletin for details. MIXING AND CURING: See p. 32. See Technical Bulletin for details regarding mixing, curing and use of additives to thicken for brush-on application (e.g., fumed silica, Poly Fiber II, and Part D). USING THE MOLD: See p. 32 and Technical Bulletin. SOFTER MOLDS: Add Part C Softener to Part B before mixing with Part A. Consult Technical Bulletin for details. STORAGE: Poly 72-40 rubber remains usable for at least 6 months from the date of shipment in unopened containers, stored in a cool, dry location. Cured molds slowly soften with age. Adequate mixing of components in the proper mix ratio contributes to long mold life as will storage of molds in a dark, cool, dry area. With proper care, Poly 72-40 molds should not soften appreciably for 24 years. Molds should be discarded before they become too soft to handle. Do not store molds outdoors, as exposure to sunlight and excessive humidity will cause rapid deterioration of the rubber. PHYSICAL PROPERTIES Mix Ratio, By Weight Hardness, Shore A Pour Time (min) Cured Color Mixed Viscosity (cP) Specific Volume (in3/lb) Shrinkage Upon Cure 1A:10B 40 30 Ivory 4,000 20 Nil

PACKAGING Poly-Fast 72-40 and Poly 72-40 MF

Mix Ratio 1A:10B (By Weight) Unit Weight (lb) Part A (lb) 9.9 49.5 495 0.9 4.5 45.0 Unit Components Part B (lb) 9.0 45.0 450 Part A
(Volume)

Part B
(Volume)

1 pt gal 5 gal

1 gal 5 gal 55 gal

Poly GlassRub Liquid Rubber

Poly GlassRub 50 RTV Liquid Rubber consists of two parts (A & B) that, after mixing, cure at room temperature to a flexible, clear rubber. Poly GlassRub 50 is designed for making clear molds that can be easily cut away from original objects with less chance of damage and better seam positioning since objects are visible through the rubber. Additionally, clear rubber castings or objects encapsulated in the clear rubber can make interesting original art or displays. Cured GlassRub may yellow slightly over time or following UV exposure. PolyColors can be added to the liquid rubber to make a tinted or colored, yet still clear, rubber. The smallest addition of a PolyColor virtually eliminates post-cure yellowing. For more information, consult the GlassRub Technical Bulletin.

FEATURES
Glass-like appearance (clear, pale blue) Reproduces fine detail Easy-to-use formulation -- 1A to 1B mix ratio Low viscosity mix with excellent bubble-release Long working time

PHYSICAL PROPERTIES
Mix Ratio, By Weight or Volume Hardness, Shore A Pour Time, 1-lb mix (min) Demold Time (hr) Specific Gravity Color, Cured Viscosity, 2.5 min after mix (cP) Specific Volume(in3/lb) 1A:1B 45-50 45 16 1.0 Glass Like/Blue-Clear* 1000 27.5

GlassRub 50 Liquid Rubber Packaging 1A:1B Mix Ratio

Weight Volume B (lb) 2 8 40 450 A 1 qt 1 gal 5 gal 55 gal B 1 qt 1 gal 5 gal 55 gal

Unit Weight
A (lb)

4 lb 16 lb 80 lb 900 lb

2 8 40 450

* Upon exposure to UV light (i.e., fluorescent light or sunlight), cured rubber may yellow with age.

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Polyurethane Mold Rubber

Silicone RTV Mold Rubbers

Poly-Sil Silicone RTV Liquid Mold Rubbers

The Poly-Sil Silicone RTV Liquid Mold Rubbers each consist of a Part A and Part B, which, after mixing, cure at room temperature to flexible, high-strength, mold rubbers. Poly-Sil Mold Rubbers make molds that are easy releasing and stable at higher temperatures. They are excellent for casting plasters, waxes, cements, low melting metals and many resins such as epoxies, polyesters, urethanes and acrylics. As with other Polytek elastomers, the last two digits in the product name indicate the approximate Shore A hardness of the cured rubber. Poly-Sil rubbers range in hardness from a very soft A10 to a firm A60. Silicone Mold Rubber MODEL PREPARATION Porous models such as wood or plaster should be sealed to prevent penetration of the rubber into the pores of the material. Wax, petroleum jelly, lacquer, paint and most other coatings are suitable sealers. Materials that will contact the rubber can be sprayed or coated with a light coat of Pol-Ease 2350, which functions as a sealer and release agent. Allow the Pol-Ease 2350 to dry before applying liquid rubber. Silicone-based release agents (i.e., Pol-Ease 2300) are not to be used on surfaces that contact liquid Poly-Sil rubbers since inhibition and/or adhesion may occur. In addition, modeling clays containing sulfur may inhibit curing. In every case where there is any question about the compatibility between the rubber and the prepared model surface, a test cure should be made on an identical surface to determine that complete curing and good release are obtained. Poly-Sil rubbers may bond to cured silicone rubbers unless a parting agent is used. Porous models must be vented from beneath to prevent trapped air from forming bubbles in the rubber (see p. 12). MIXING AND CURING Before mixing rubber, be sure that both Parts A and B are at room temperature and that all tools and models are ready to go! Check product labels or technical bulletins to determine working time for the product -- some products set fast -- meaning that you must work quickly. Many Poly-Sil Part As require stirring before use. If there is a Stir Before Use label on the container -- be sure to do so.
Molds made from highperformance Poly-Sil rubbers are best for casting harsh resins. This gargoyle blanket mold made of soft PlatSil 71-11 easily pulls off the cast resin part. The smooth, release-free demold of silicone is especially welcome on highly detailed parts.

POLY-SIL MOLD RUBBERS: AT A GLANCE

TinSil 70 Series - Tin-catalyzed silicone systems that cure to tough, high-performance rubbers with easy release properties and resistance to high temperatures. Great for casting polyester resin. PlatSil 71 Series - High-tear strength, platinum-cured silicone systems with hardness up to A40. Excellent for casting polyurethane resins and dimensionally accurate prototype parts. PlatSil 73 Series - High-tear strength, tough, platinumcured silicone systems with hardness up to A60. Excellent for casting polyurethane foams and dimensionally accurate prototype parts. PlatSil Gel 10 - A soft, translucent rubber for delicate casting projects and special effects applications. Mix Ratios Vary! Check the mix ratios for the specific product you are using. For Poly-Sil rubbers, most mix ratios are expressed by weight. Carefully weigh Parts A and B in proper ratio. Accurate weighing is essential to obtain optimum physical properties from the cured rubber. Weigh Part B into a clean metal or plastic mixing container. Then weigh the appropriate amount of Part A into the same container. Mix thoroughly, scraping sides and bottom of the container. Hand mixing with a Poly Paddle (see p. 62) is best to avoid mixing air into the rubber. To ensure a bubble-free mold, deaerate the liquid rubber under vacuum at 28-29 inches mercury until the mass of rubber rises and then collapses. Deaerate for an additional 2 minutes. For vacuuming, use a mixing container 3 to 4 times larger than the volume of rubber. Pour the rubber as soon after mixing as possible for best flow and air bubble release. If reinforcement of the rubber is needed (i.e., in thin blanket molds), place stretchy, open mesh nylon or dacron cloth into the uncured rubber. Be sure that the fabric is not too close to the mold surface or the weave of the cloth may show through to the face of the mold. Check product labels or technical bulletins to determine cure times. To reach full hardness in the specified demold time, temperature should be above 77F (25C). At lower temperatures, more time may be needed to reach full hardness. Curing below 65F (18C) is not recommended. For most Poly-Sil products, final cure properties are obtained in about seven days, but most molds may be used with care after curing for 24 to 48 hours. USING THE MOLD No release agent is necessary for casting most materials in PolySil molds. For longer mold life, however, a barrier coat or release agent (i.e., Pol-Ease 2300) is recommended when casting epoxy,

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polyurethane or polyester resins. Most Poly-Sil molds can be stored for years, but tin-catalyzed silicone molds eventually deteriorate and lose their elasticity. ADDITIVES & ACCESSORIES Polytek offers various additives that can be used to vary the properties of the cured and uncured Poly-Sil rubbers. Thinner/Softener - Very low viscosity 50 cSt Silicone Fluid can be added sparingly to the mixed rubber to thin the mix with some loss of strength, hardness and cure speed. More than 10% fluid addition may exude from the cured rubber. Accelerator - A specially formulated accelerator can be added to most Poly-Sil products to reduce the cure time. Thickener - Specially formulated chemical thickeners can be added to most Poly-Sil products to make the liquid rubber thicker (i.e., for brush-on application). Cab-O-Sil Fumed Silica, which is both a thickener and thixotropic agent, can also be added to mixed Parts A and B in order to form a gel appropriate for application by brush or trowel. Colors - Certain Poly-Sil rubbers can be tinted to various shades by adding small amounts of colors. Barrier Coat - A barrier coat (i.e., Barrier PF) is a fast drying, lacquer-like primer that is sprayed into a silicone mold and allowed to dry prior to pouring plastic. The plastic cures against the barrier coat and comes out on the plastic casting resulting in a pre-primed part. Using a barrier coat may extend mold life. To learn more about additives, refer to product technical bulletins or call Polytek Customer Service. See additives and accessories for Poly-Sil products in the box to the right. CLEAN UP Tools should be wiped clean before the rubber cures. Denatured ethanol is a good cleaning solvent, but it must be handled with extreme caution owing to its flammability and health hazards. SAFETY Before use, read product labels and Material Safety Data Sheets. Follow safety precautions and directions. Contact with uncured products may cause eye, skin and/or respiratory irritation. Avoid contact with skin and eyes. If skin contact occurs, remove with waterless hand cleaner or alcohol then soap and water. In case of eye contact, flush with water for 15 minutes and call a physician. Use only with adequate ventilation. Poly-Sil products are not to be used where food or body contact may occur. STORAGE LIFE At least six months in unopened containers stored at room temperature (60-90F).

TINSIL & PLATSIL ACCESSORIES

Pol-Ease 2300 Release Agent 12-oz can, case of 12 cans Pol-Ease 2350 Release Agent 1 qt (1.5 lb), 5 gal (26 lb) Pol-Ease 2500 Release Agent 12-oz can, case of 12 cans Silicone Fluid 50 cSt Grade For Thinning Poly-Sil Rubbers 1 qt (2 lb), 1 gal (8 lb), 5 gal (40 lb) TinSil FastCat 4 oz, 1 pt (1 lb), 1 gal (8 lb)

PlatSil 71/73X Accelerator 4 oz, 1 pt (1 lb), 1 gal (8 lb) PlatSil 71R Retarder 4 oz, 1 pt (1 lb), 1 gal (8 lb), 5 gal (40 lb) PlatThix 4 oz, 1 pt (1 lb) Barrier PF 1 qt (1.5 lb), 5 gal (35 lb) Cab-O-Sil/Fumed Silica 5 gal, 1 bag (10 lb) Smiths Theatrical Prosthetic Deadener 1 qt (2 lb), 1 gal (8 lb), 5 gal (40 lb)

CAUTION! -- Certain chemicals cause cure inhibition in silicone rubbers. Beware of amines, polyesters and tin compounds with PlatSil systems. Sulfur compounds can affect both PlatSil and TinSil systems. Perform a test cure!

Poly-Sil rubber blanket molds reproduce the fine details of models and are soft and tough enough to easily pull off complex castings. Usually, the more intricate the model/casting, the softer the mold rubber selected. This very ornate column capital was easily cast in TinSil 70-11. The gargoyle mold was made using PlatSil 7120. The large, multi-piece, Ronald McDonald mold was made using TinSil 70-30 to cast numerous polyester resin parts.

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Silicone Mold Rubber

TinThix 4 oz, 1 pt (1 lb)

Silicone RTV Mold Rubbers

TinSil 70 Series
DESCRIPTION: TinSil 70 Series RTV Silicone Rubbers are condensation-cure, tin-catalyzed, flexible mold rubbers. TinSil products consist of a liquid Part B base and Part A accelerator, which, after mixing at the proper ratio by weight, cure at room temperature to rubber with a tough, knotty tear property. TinSil molds have easy release properties and are resistant to high temperatures. TinSil molds are excellent for casting polyesters, epoxy and polyurethane resins; waxes and many other materials. Choose the appropriate hardness of rubber for your application. TinSil 70-11, 70-20 and Gel-10 are soft and, therefore, best for delicate castings. Gel-10 is translucent and especially useful for animatronics and special effects. TinSil 70-25 and 70-30 are Polyteks most popular and versatile, mid-range hardness, silicone rubbers. TinSil Spray-25 is sprayable or brushable and can be applied by hand or sprayed with a low-cost Plas-Pak spray gun or more sophisicated 1A:10B silicone spray equipment. Spray 25 is great for large scale blanket molds! TinSil 70-39 is firm with excellent tear properties making it popular for casting polyurethane foams and plastic prototypes. TinSil 70-60 is stable at higher temperatures making it suitable for casting low melting metals. TinSil 70-60 has limited tear strength because of its hardness. MODEL PREPARATION: See p. 40. MIXING AND CURING: See p. 40. CAUTION! TinSil products release alcohol while curing, which results in slight shrinkage of the rubber (up to 1%) and can inhibit the surface cure of some polyurethanes. If shrinkage cannot be tolerated, consider PlatSil rubbers. Before casting polyurethanes in a TinSil mold, evaporate alcohol by letting the mold sit in a warm location for 24 hours or by baking the mold for 4 hours at ~200F. USING THE MOLD: See p. 40. [Note: Molds made with excess catalyst may be subject to faster degradation on aging.] ACCELERATING CURE SPEED: Use TinSil FastCat in place of any TinSil Part A in order to accelerate cure and shorten demold time. FastCat can be used in a range of 2-6 parts per 100 parts B; see product technical bulletin for details. Use of FastCat can shorten the library life of cured TinSil rubber. THICKENING FOR BRUSH ON: Add TinThix liquid thickener or Cab-O-Sil to liquid TinSil rubbers for brushing on a blanket mold. TinThix can be mixed into the Part B (before mixing with Part A) to achieve varying levels of thixotropy. ACCESSORIES: See box on p. 41. SAFETY: See p. 41.

Silicone Mold Rubber

TinSil Physical Properties

70-11 & Gel-10 Mix Ratio (By Weight) Hardness, Shore A Pour Time (min) Demold Time @ 77F (hr) Color Mixed Viscosity (cP) Specific Volume (in /lb)
3

70-20 1A:10B 20 60 16 Blue 10,000 25.3 1.1 ~0.3

70-25 1A:10B 25 60 16 Blue 14,000 25.3 1.1 ~0.3

Spray-25 1A:10B 25 30 16-24 Translucent Thixotropic 25.3 1.1 ~0.3

70-30 2A:100B 30 60 24 Beige 26,000 25.3 1.1 ~0.3

70-39 1A:10B 40 45 16 Blue 25,000 21.7 1.27 ~0.3

70-60 5A:100B 60 30 24 Red 17,000 18 1.5 ~0.8

1A:10B 10 45 16 Blue (70-11) Transluscent (Gel-10) 10,000 25.3 1.1 ~0.3

Specific Gravity Shrinkage Upon Cure (%)

TinSil Product
Gel-10, 70-11, 70-20, 70-25, Spray 25 and 70-39 Mix Ratio 1A:10B

TinSil Packaging
Unit Sizes (lb) 1.0 2.0 (Spray 25 Cartridge) 9.0 44.0 495 1.02 8.3 40.8 448.8 1.05 8.4 42.0 Part A (lb) 0.1 0.2 0.9 4.0 45.0 0.02 0.2 0.8 8.8 0.05 0.4 2.0 Part B (lb) 0.9 1.8 8.1 40.0 450 1.0 8.1 40.0 440 1.0 8.0 40.0 (610)559-8620 (800)858-5990

70-30 Mix Ratio 2A:100B 70-60 Mix Ratio 5A:100B

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Silicone RTV Mold Rubbers

PlatSil 71 Series
DESCRIPTION: PlatSil 71 Series RTV Silicone Rubbers are two-component, addition-cure, platinum-catalyzed, flexible mold compounds. The 71 Series products exhibit a tough, knotty tear, making them especially valuable to the mold making industry. They are excellent mold materials for casting polyester, epoxy and polyurethane resins, as well as for waxes and many other materials. PlatSil 71 Series products offer advantages over tincatalyzed systems in certain applications because on curing they dont shrink and dont produce alcohol (like tin-catalyzed silicones), which can inhibit polyurethane castings. MODEL PREPARATION: See p. 40. MIXING & CURING: See p. 40. USING THE MOLD: See p. 40. ACCELERATING CURE SPEED: Accelerate the cure with heat or the addition of PlatSil 71/73X. Mix 71/73X with Part B prior to adding Part A. Weigh and add Part A to the accelerated Part B mixture and mix thoroughly. Pour over a properly prepared model as soon after mixing as possible. The addition of 1 part 71/73X per 100 parts of Part B decreases the gel time to ~1/3 the normal gel time. The addition of 2 parts decreases the normal gel time to ~1/4. The addition of 3 parts decreases the normal gel time to ~1/6. Experimentation on a small scale is recommended before making a larger mix.

FEATURES
Easy mix ratios; some 1:1 mixes available Cure at room temperature or accelerate with heat Easy release properties -- save on release agents High tear strength -- fewer prematurely torn molds Good chemical resistance for longer mold life Low/zero shrinkage for dimensional reproduction Range of hardnesses from A10 to A40 Silicone Mold Rubber 43

RETARDING CURE SPEED: PlatSil 71R added to PlatSil Part A prior to mixing with Part B slows the cure yielding longer working time and longer demold time. Adding ~1% of 71R to the total mixed weight of PlatSil A+B roughly doubles the working time. Adding ~2% of 71R triples working time. Do not use more than 4% as the system may not cure at all. THICKENING FOR BRUSH ON: For brushing on skin mold, thicken PlatSil 71 Series rubbers with PlatThix or Cab-O-Sil. When brushing PlatSil 71-11 or 71-20, apply subsequent coats to the previous layer within one hour to obtain best adhesion. ACCESSORIES: See box on p. 41. SAFETY: See p. 41.

PHYSICAL PROPERTIES
Mix Ratio (By Weight) Hardness, Shore A Pour Time (min) Demold Time (hr) @ 77F Color Mixed Viscosity (cP) Specific Volume (in3/lb) Specific Gravity Shrinkage Upon Cure 71-10 1A:10B 10 5 0.5 Pink 3,500 26 1.06 Nil 71-11 1A:1B 10 20 4 Blue Green 6,000 24.7 1.12 Nil 71-20 1A:1B 20 25 4 Lt. Purple 12,000 24.7 1.12 Nil PACKAGING Product PlatSil 71-11, 71-20 Mix Ratio 1A:1B PlatSil 71-10, 71-30, 71-35 Mix Ratio 1A:10B Unit Weight (lb) 2.0 16.0 80 1.0 9.0 44.0 495 9.8 48.0 528 Size A 1 pt 1 gal 5 gal 4 oz 1 pt gal 6 gal 1 qt 1 gal 2 x 6 gal B 1 pt 1 gal 5 gal 1 pt 1 gal 5 gal 55 gal 1 gal 5 gal 55 gal A 1.0 8.0 40.0 0.1 0.9 4.0 45.0 1.7 8.0 88 Net Weight (lb) B 1.0 8.0 40.0 0.9 8.1 40.0 450 8.1 40 440 71-30 1A:10B 30 60 24 Lt.Green 25,000 24.7 1.12 Nil 71-35 1A:10B 35 60 24 Blue 25,000 24.7 1.12 Nil 71-40 1A:5B 40 60 24 Hazy transparent 25,000 25 1.10 Nil

PlatSil 71-40 Mix Ratio 1A:5B

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Silicone RTV Mold Rubbers

PlatSil 73 Series
DESCRIPTION: PlatSil 73 Series RTV Silicone Rubbers are two-component, high-tear strength, flexible mold compounds. The 73 Series rubbers are excellent mold materials for many casting materials including polyester, epoxy and polyurethane resins. PlatSil 73 Series silicones are addition-cure, platinumcatalyzed systems and offer advantages over tin-catalyzed systems in certain applications because on curing they dont shrink, they dont produce alcohol, which can inhibit urethane castings, and their cure can be heat accelerated. MODEL PREPARATION: See p. 40. MIXING & CURING: See p. 40. Silicone Mold Rubber USING THE MOLD: See p. 40. ACCELERATING CURE SPEED: Accelerate the cure with heat or the addition of PlatSil 71/73X. Weigh and add 71/73X to Part B and mix. Weigh and add Part A to the accelerated Part B mixture and mix thoroughly. Pour over a properly prepared model as soon after mixing as possible. Demold when tack free. The addition of 1 part 71/73X per 100 parts of Part B decreases the gel time to ~35 min. The addition of 2 parts decreases the gel time to ~30 min. The addition of 3 parts decreases the gel time to ~25 min. The addition of 71/73X softens the cured rubber slightly. Remember, heat accelerates the cure; low temperatures slow the cure.

FEATURES
Low viscosity for excellent detail reproduction and easy degassing. Easy 10A:100B mix ratio -- can use with dispensing machines Cure at room temperature or accelerate with heat Easy release properties -- save on release agents High tear strength -- fewer prematurely torn molds Good chemical resistance for longer mold life Low/zero shrinkage for better dimensional reproduction Range of hardnesses from A30 to A60

THICKENING FOR BRUSH ON: PlatSil 73 Series rubbers can be thickened with PlatThix liquid thickener or with Cab-O-Sil for brushing on a blanket mold. ACCESSORIES: See box on p. 41. SAFETY: See p. 41.

PHYSICAL PROPERTIES
Mix Ratio, By Weight Hardness, Shore A Pour Time (min) Demold Time @ 77oF (hr) Color Mixed Viscosity (cP) Specific Volume (in3/lb) Specific Gravity Shrinkage Upon Cure 73-29 10A:100B 30 45 16 White 15,000 25.0 1.10 Nil 73-45 10A:100B 45 60 16 Green 35,000 21.3 1.30 Nil 73-60 10A:100B 60 45 16 Blue 40,000 21.3 1.30 Nil

PACKAGING
PlatSil 73-29, 73-45, 73-60 Mix Ratio 10A:100B Unit Weight (lb) 1.0 9.0 44.0 495 (73-29) 550 Size A 4 oz 1 pt 0.5 gal 6 gal 6 gal B 1 pt 1 gal 5 gal 55 gal 55 gal Components Net Weight (lb) A 0.1 0.9 4.0 45.0 50.0 B 0.9 8.1 40.0 450 500

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PlatSil Gel-10
DESCRIPTION: Platil Gel-10, a translucent, soft rubber, is an excellent mold material for delicate casting projects and creating special effects. Gel-10 is a two-part, addition cure, liquid silicone system with an easy 1:1 mix ratio. After mixing Parts A and B, Gel-10 cures within 30 minutes at room temperature to a soft, tough rubber. Gel-10 does not shrink on curing. For special effects, soften PlatSil Gel-10 by adding Smiths Theatrical Prosthetic Deadener. Deadened PlatSil Gel-10 is excellent for creating skins and self-sticking appliances. MODEL PREPARATION: See p. 40. MIXING AND CURING: See p. 40. Normal mixes gel in approximately 6 minutes at room temperature; faster if warm, slower if cold. Immediately place the mix over the model or in the mold. There is not normally adequate time for vacuum (unless retarder is used), but pressure casting may be useful to eliminate bubbles. Contamination with soaps, amines, sulfur, tin compounds and some RTV Silicone Rubbers may inhibit surface cure. USING THE MOLD: For best results, allow PlatSil Gel-10 to cure for at least 1 hour before use. No release agent is necessary for casting most materials in properly cured PlatSil Gel-10. For longer mold life, however, use a barrier coat or release agent when casting epoxy, polyurethane or polyester resins. ACCELERATING CURE SPEED:Mix PlatSil 71/73X into Part B prior to adding Part A to accelerate gel time and cure. See product technical bulletin for details. RETARDING CURE SPEED: Add PlatSil 71R to Part A prior to mixing with Part B to slow the cure for longer working time and demold time. Add 71R at 1% of the weight of total mix (A+B) to double the working time. Add up to 5% for a 60minute work time with 120-minute demold time. THICKENING FOR BRUSH ON: Thicken with TinThix liquid thickener or with Cab-O-Sil for brush-on application. Add 1% TinThix to the total mix weight for a light-bodied, non-sag gel. SMITHS THEATRICAL PROSTHETIC DEADENER: Add up to 250% of Smiths Deadener to the total Gel-10 mix weight (A+B) to create super soft, gel-like, self-sticking prosthetics or gel-filled appliances. If applied behind a casting of straight PHYSICAL PROPERTIES
Mix ratio, by weight Hardness, Shore A Pour time, minimum Demold time @ 25C (77F) Color Viscosity, mixed Specific volume (in3/lb) Specific gravity @ 25C (77F) Shrinkage upon cure www.polytek.com 1A:1B 10 + 2 6 min 30 min Colorless 15,000 cP 25 1.10 Nil

FEATURES
Soft (~A10), translucent, silicone rubber Easy 1:1 mix ratio Fast 30-minute demold with 6-minute work time PlatSil 71R Retarder slows the cure PlatSil 71/73X Accelerator speeds the cure PlatThix thickens the mix to a brushable paste Bonds to Poly Plastics

The term deadener was coined by Gordon Smith of FXSmith, who developed this additive. Deadened Gel-10 does not have the springy, snappy feel typical of silicone rubber, but rather resembles the feel of human tissue. Go to www.fxsmith.com for more information. BONDING TO PLASTICS: PlatSil Gel-10 bonds to clean, cured Poly 15 Series plastics that are less than 24-hours old. See product technical bulletin for details. ACCESSORIES: See box on p. 41. SAFETY: See p. 41.
David Gavin and colleagues from Arran Studios in Cork, Ireland, proudly display their Velociraptor casting made with life-like PlatSil Gel-10 skin. PlatSil Gel-10 makes great animatronic skins. The product can be softened with the addition of Silicone Fluid and colored to make the look and feel just right.

PACKAGING
Mix Ratio: 1A:1B (By Volume) Unit Weight (lb) A 2.0 16.0 80.0 1 pt 1 gal 5 gal Size B 1 pt 1 gal 5 gal Containers Net Weight (lb) A 1.0 8.0 40.0 B 1.0 8.0 40.0

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Silicone Mold Rubber

PlatSil Gel-10, the underlying gel can mimic the slow stretch and recovery properties of human tissue. Pigments can be added to PlatSil Gel-10 and/or Deadener to achieve any color needed.

Casting Plastics/Resins

Casting & Mold Shell Plastics

Polytek liquid plastics are two-part systems that can be used to cast decorative objects, parts, tools, and patterns as well as to create lightweight mold shells to support brushed or sprayed blanket molds. Polytek plastics can mimic materials of nearly any density and appearance including lightweight foams, thermoplastics, glass, wood, stone and metals. The products can be poured, layed up or sprayed to accommodate any size casting or object. Varying viscosities, pot-lives, cure times and physical properties allow the user to choose a plastic tailored to their particular needs. The versatility of Polytek Plastics is unlimited. MOLD PREPARATION Before pouring or applying liquid casting plastics, be sure that the surface is properly prepared in order to prevent the plastic from sticking or foaming. Polyethylene and silicone rubber molds, such as TinSil and PlatSil products, do not require a release agent, but a barrier coat may be helpful. Latex, polyurethane rubber or metal molds must be dry and require a coat of Pol-Ease 2300 Release Agent. A trial casting or application should be made to avoid damaging a valuable mold and/or wasting liquid plastic. Casting Plastics When using Poly Plastics to create lightweight mold shells, prepare the rubber mold surface as described on p. 20. Poly 15-6, 1511 and Poly 1512X can be mixed with Poly Fiber to thicken the pourable plastics to a thixotropic consistency that can be applied to vertical and horizontal surfaces like frosting a cake. This process is described in more detail on p. 22. MIXING Before mixing resins, be sure that both Parts A and B are at room temperature and that all tools and molds are ready to go! Use metal or plastic mixing vessels (i.e., polyethylene pail) and spatulas to avoid introducing moisture. Check product labels or technical bulletins to determine working time for the product -- some products set fast -- meaning that you must work quickly. Some Polytek plastics require stirring before use. If there is a Stir Before Use label on the container -- be sure to do so. Mix Ratios Vary! Check the mix ratios for the specific product you are using. Carefully weigh/measure Parts A and B in proper ratio. Accurate weighing/measuring is essential to obtain optimum physical properties from the cured plastic. Weigh/measure Part B into a clean metal or plastic mixing container. Then weigh/measure the appropriate amount of Part A into the same container. Mix thoroughly, scraping sides and bottom of the container. Hand mixing with a Poly Paddle (see p. 62) is best to avoid mixing air into the plastic. Pour mix into mold cavity or apply to surface as soon after mixing as possible. Once the containers of Parts A and B are opened, they should be used completely or resealed tightly as atmospheric moisture can react with the Part A or may cause foaming of the plastic. Poly Purge, a dry gas product, can be sprayed into opened containers of liquid plastics to lengthen shelf life once opened.

POLYTEK PLASTICS: AT A GLANCE

EasyFlo Series - Low viscosity, 1:1 mix by volume, fast-setting plastics. Polyteks easiest-to-use and bestselling plastics! Poly 15-Series - Strong plastics with varying densities: some are like thermoplastics, others like stone. Poly PT Series - Strong, fast-curing, flame-retardant plastics for prototyping and model making. Also available in low-viscosity, fast-curing rubber formulations. Request Technical Bulletin for details. Poly-Optic 14 Series - Water clear, non-yellowing casting resins for speciality applications demanding clear, bubble-free castings. PolyFoam Series - Low viscosity, 1:1 mix ratio, fastsetting rigid and flexible foams. Poly LiteCast - Easy, 1:1 mix ratio plastic with a woodlike density. Poly Plasti-Flex - Innovative flexible plastic for architectural moldings that bend, props and more. Polygel Plastic-75 - Thickens to a paste upon mixing and cures in 2-4 hours. Makes great mold shells fast. Polygel Shell - A sprayable plastic for creating mold shells, sprayed-up castings or surface hardcoats. Polypoxy Resins & Poly Cures - Epoxy systems for creating various castings including decorative bonded bronzes and tools that can withstand high heat. CURING Castings should be allowed to remain in the mold until thoroughly cured. Parts demolded too soon may be subject to deformation. Use of pre-warmed molds will hasten curing. Mold shells should not be demolded until fully cured to prevent distortion or warping. Check product labels or technical bulletins to determine appropriate demold times. To reach full hardness in the specified demold time, temperature should be above 77F (25C). At lower temperatures, more time may be needed to reach full hardness. Curing below 65F (18C) is not recommended. For most Polytek plastics, final cure properties are obtained in within 7 days. ADDITIVES & ACCESSORIES Polytek offers various additives and accessories that can be used to vary the properties of the cured plastics and/or make using the plastics easier. Accelerator/Retarder - Specially formulated chemical accelerators or retarders can be added to Polytek liquid plastics to vary the cure time. Fillers - Dry fillers or metal powders can be added to Polytek liquid plastics to vary the density and look of the cured pieces. Also, fillers can be added to make the liquid plastic thicker (i.e., for brush-on or trowel application).
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Casting Plastics/Resins
Foamer - A chemical foamer can be added to some liquid plastics to turn them into foams. Colors - PolyColors can be added to liquid plastics (see p. 61). Barrier Coat - A barrier coat (i.e., Barrier PF) is a fast drying, lacquer-like primer that is sprayed into a silicone mold and allowed to dry prior to pouring plastic. The plastic cures against the barrier coat and comes out on the plastic casting resulting in a primed part. Using a barrier coat often extends mold life.

eye contact, flush with water for 15 minutes and call a physician. Use only with adequate ventilation. Polytek plastics are not to be used where food or body contact may occur. Plastics burn readily when ignited. Care should be taken with sanding dust and other easily ignitable forms of these products. STORAGE LIFE Polytek liquid plastics can be stored for at least six months in unopened containers stored at room temperature (60-90F). Cured plastics will last indefinitely, but may discolor as noted above. In order to maintain dimensions, Poly Plastic mold shells must be stored in temperatures <100F. Also, the shells must not be distorted in storage (e.g., no heavy objects placed on top).

To learn more about additives, refer to product-specific technical bulletins or call Polytek Customer Service. Additives and accessories for Polytek plastics are listed in the box to the right. FINISHING Many cured plastics yellow slightly and chalk when exposed to sunlight and, therefore, should be painted or sealed for exterior use. If they are to be painted or coated, adhesion of the coating should be checked carefully over a period of time to determine that it is satisfactory for the intended use. If all mold release is removed by detergent washing, most oil paints work well. Castings can be drilled, sanded and machined. CLEAN UP Tools should be scraped clean before the plastic is hard. Denatured ethanol is a good cleaning solvent, but it must be handled with extreme caution owing to its flammability and health hazards. Work surfaces can be waxed or coated with Pol-Ease 2300 Release Agent so cured rubber can be removed. SAFETY Before use, read product labels and Material Safety Data Sheets. Follow safety precautions and directions. Contact with uncured products may cause eye, skin and/or respiratory irritation. Avoid contact with skin and eyes. If skin contact occurs, remove with waterless hand cleaner or alcohol then soap and water. In case of

POLYTEK ADDITIVES & ACCESSORIES

Poly-Optic 14X Catalyst 1 oz, 1 pt (1.0 lb) Poly-Optic 14R Retarder 1 pt (1.0 lb) Part 15X Catalyst 1 oz, 1 pt (1.0 lb), 1 gal (8.0 lb) Part 15F Foamer 1 oz, 1 pt (1.0 lb), 1 gal (8.0 lb) Poly UV Additive 4 oz, 1 pt (1.0 lb) Bronze Powder 2.0 lb can, 10 lb can, 110 lb can Cab-O-Sil/Fumed Silica 5 gal, 1 bag (10 lb)

OTHER SUPPLIERS FOR FILLERS

3M - Lightweight fillers, Glass Bubbles (800) 541-6752 Ball Consulting ltd - Brass, copper and silver powders (800) 225-2673 Imerys Inc. (formerly Georgia Marble Co.) - Marble powders (888) 277-9636 Mahogany Co. - Various fillers (609) 625-8101 PQ Corp. - Lightweight fillers, Extendospheres, Q-cells (800) 252-0039 The R.J. Marshall Co. - Aluminum Tihydrate, OnyxFill, etc. (248) 353-4100 Trelleborg Fillite Inc. - Hollow ceramic microspheres (770) 729-8030

Poly Fiber II 5 gal, 1 bag (10 lb) Pol-Ease 2300 Release Agent 12-oz can, case of 12 cans Pol-Ease 2500 Release Agent (Cleanable/Paintable) 12-oz can, case of 12 cans Pol-Ease PF Release Agent 1 qt (2.0 lb), 5 gal (40 lb) Barrier PF Barrier Coat 1 qt (2.0 lb), 5 gal (40 lb) Poly Purge 10-oz can, case of 12 cans PolyColors Red, Green, Yellow, Blue, Brown & Black 4-oz bottle (0.25 lb), 1.0 pint (1.0 lb)

www.polytek.com

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Casting Plastics

Casting Plastics/Resins

EasyFlo Series Liquid Plastics

DESCRIPTION: EasyFlo Liquid Plastics are excellent for casting decorative objects, production parts, tools, models, duplicate masters and more. EasyFlo systems consist of two parts (A and B) that, after mixing, quickly cure to tough polyurethane plastics. Since Parts A and B are super- low viscosity liquids, they are easy to mix, provide excellent detail penetration, and make bubble-free castings without vacuum degassing or pressure casting techniques. Rapid demold times make EasyFlo ideal for high-volume, fastcast applications. Choose the EasyFlo Liquid Plastic thats best for your application: EasyFlo 60 pours like water, so making bubble free parts is easy and fast (2-min working time, 10-min demold). EasyFlo 95 is useful when longer working time (5 min) is needed to complete a pour. For thin parts, demold time is longer and molds may need to be preheated (100-120F) to reduce surface bubbles and speed demold. EasyFlo 120 is best for rotocasting or slush casting to create hollow parts. Hollow parts are nearly unbreakable! EasyFlo Clear cures to a pale amber color. Add PolyColors to make transparent, colored castings. Its excellent in applications using fillers intended for visual appeal (e.g., bronze). Heated molds and pressure casting techniques are recommended. MOLD PREPARATION: See p. 46. MIXING: Measure equal volumes of A and B into a mixing container such as a polyethylene pail. Mix immediately and thoroughly for one minute. See p. 46 for more information. PHYSICAL PROPERTIES
EasyFlo Product Mix Ratio, By Volume Mix Ratio, By Weight Hardness, Shore D Pour Time (min; 1-lb mix) Demold Time (min) Specific Gravity Cured Color Initial Mixed Viscosity (cP) Specific Volume (in /lb)
3

FEATURES
Easy 1:1 mix ratio by volume Extremely low viscosity -- pours like water Sets fast with rapid demold Reproduces finest details Tough, non-brittle formula Excellent bubble release without vacuum or pressure Readily accepts high filler levels Low odor

Casting Plastics

CURING: See p. 46. ADDITIVES: Various fillers (bronze powder, microballoons, calcium carbonate, sand, granite, etc.) can be added as desired. Fillers must be thoroughly dried before mixing with resin. PolyColors (see p. 61) can be added to EasyFlo Part B before mixing with Part A to create plastic of any color desired. FINISHING: See p. 47. CLEAN UP: See p. 47. SAFETY: See p. 47.
These bronze castings were created quickly and easily by mixing bronze powder with EasyFlo 60 Liquid Plastic. Large castings such as this 10-inch tall Zeus head can be rotocast with EasyFlo 120 to create hollow parts weighing a fraction of the weight of solid castings.

60 1A:1B 100A:90B 65 2-2.5 15-30 1.03 White 60 26.9 230

95 1A:1B 100A:90B 65 5 20-60 1.03 Off White 95 26.9 206

120 1A:1B

Clear 1A:1B

100A:90B 100A:90B 65 2-2.5 15-30 1.03 White 120 26.9 200 72 2-2.5 15-30 1.03 Amber 110 26.9 208

Note on Cold-Cast Bronze

Bronze and other metal powders are rather expensive; but only a thin coating of resin mixed with bronze need be brushed or slush-cast against the face of the mold. Estimate the volume of liquid resin and bronze required by considering the surface area to be covered by the thinnest possible layer. If needed, multiple mixes can be made and patched one against the other before they fully cure. The recipe for the EasyFlo 60/bronze powder mix is as follows. Mix 1 part (by volume) EasyFlo 60 A with 1 part (by volume) EasyFlo 60 B and blend for a few seconds. Then add 2 parts (by volume) bronze powder to the mixed EasyFlo and mix well to wet the powder. This mix will be thick and may not flow into all the mold detail, so brushing may be needed. Once the face of the mold is evenly coated with a thin layer of resin/bronze it can be back-filled with a heavy, solid pour resin such as 15-3X. 15-3X resin will make it "feel" like bronze without the cost of filling the entire space with expensive bronze powder. Once cured, the casting can be removed and burnished with 0000 steel wool. Apply a patina by spraying green and black oil-based paint and wiping with mineral spirits or use a cold chemical patina such as Super Antik 40. The results can be amazing!

Maximum Exotherm (F)

PACKAGING
Product(s) Part A (lb) 1 qt (2.0) EasyFlo 60, 95, 120, & Clear 1 gal (8.0) 5 gal (40.0) 55 gal (450) Part B (lb) 1 qt (1.8) 1 gal (7.2) 5 gal (36.0) 55 gal (405) Unit 3.8 lb 15.2 lb 76.0 lb 855 lb

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Casting Plastics/Resins

Poly 15 Series Liquid Plastics

DESCRIPTION: Poly 15 Series Liquid Plastics are excellent for casting decorative fixtures, production parts, tools, models, patterns, duplicate masters, mold shells and more. Poly 15-6, 1510, 1511, 1512 and 1512X Plastics have the feel and density of wood or thermoplastics. Poly 15-3 and 15-3X Plastics resemble stone. Poly 15-8 is an aluminum-filled system that is ideal for applications where heat resistance and thermal conductivity are required (i.e., vacuum forming). Poly 15-6, 1511 and 1512X can be mixed with Poly Fiber II to create tough, lightweight mold shells. With proper equipment and acceleration, Poly 1512 can be sprayed for hardcoating or to make sprayed-up castings. If water-clear, non-yellowing plastics are needed, consider Poly-Optic products (p. 51). MOLD PREPARATION: See p. 46. MIXING: See p. 46. CURING: See p. 46. ADDITIVES: Part 15X Catalyst increases the speed of curing (see box on next page). Stir Part X into Part B before adding Part A. A few drops in a 1-lb mix speeds the cure significantly. Exotherm (heat of reaction; see p. 6) and thus shrinkage may be increased. Experiment to determine the best amount of Part X to use, but never use more than 1% Part X of the total weight of the mix or the final physical properties may be affected. Part 15F Foamer can be added to Poly 15-6 and 1510 to create rigid, open-cell foams with densities as low as 6 lb/ft3. Part F Foamer should be stirred into the Part B before adding Part A. Experiment to determine the best amount of Part F for the application at hand, but never use more than 3% Part F of the total weight of the mix or the final physical properties may be affected. For self-skinning foams, consider PolyFoam products (see p. 53). If a paste-like consistency is needed for application, add Poly Fiber II to thicken the mix

FEATURES
Easy -- 1:1 mix ratio formulations Reproduces fine details Can be machined, drilled, sanded Tough and hard, but not brittle Lightweight for mold shells Low shrinkage upon cure Air bubbles rise and break Long working time or instant set with 15X Low odor formula Castable in large masses Sprayable for hardcoating

PolyColors (see p. 61) can be added to some 15 Series Part Bs before mixing with Part A to create colored plastics. FINISHING: See p. 47. STORAGE: In order to maintain dimensions, Poly Plastic mold shells must be stored in temperatures <100F. Also, the shells must not be distorted in storage (e.g., no heavy objects placed on top). See p. 47. CLEAN UP: See p. 47. SAFETY: See p. 47.

PHYSICAL PROPERTIES 15-3/15-3X

Mix Ratio (By Weight) Hardness, Shore D Pour Time, 1-lb mix (min) Maximum Exotherm, 1-lb mass Demold Time (hr) (varies with 15X) Specific Gravity Color, Cured Viscosity, 2-min after mix (cP) Specific Volume (in3/lb) Shrinkage Upon Cure (in/in) 1A:1B 80 15 (15-3) 5 (15-3X) 122F (50C) 12 (15-3) 1 (15-3X) 1.53 Tan 2,000 18 0.0002* (15-3) 0.008* (15-3X)

15-6
1A:1B 72 5 203F (95C) 1-3 1.08 Tan 800 26 0.003*

15-8
26A:100B 80 30 131F (55C) 1-16 1.57 Gray 6,000 17.6 0.0002

1510
1A:1B 71 19 264F (129C) 1-16 1.08 Off-White 160 26 Very low*

1511
1A:1B 71 8-10 251F (122C) 0.5-1 1.10 White 400 25.1 Very low*

1512/1512X
1A:1B 71 22 (1512) 5 (1512X) 251F (122C) 1-16 (1512) 0.5 (1512X) 1.10 White 400 25.1 Very low*

*Shrinkage is primarily caused by gelling while hot then cooling. Parts that cure with minimal temperature rise usually exhibit minimal shrinkage.

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49

Casting Plastics

Add fillers as needed to vary the density and appearance of the cured plastic. Microballoons can be added to create a wood-like, density. Other fillers include metal (e.g., bronze) or stone (e.g., calcium carbonate) powders. Add fillers after Parts A and B are mixed. Fillers must be thoroughly dried before mixing with resin.

Casting Plastics/Resins
Polytek is proud to share its hometown, Easton, PA, with Crayola Inc. The larger-than-life crayons falling from the roof of the Crayola Factory Visitors Center were cast in Poly 15-6 Liquid Plastic.

Poly 15 Series Liquid Plastics reproduce the finest detail. Fillers can be added to Poly 15 Series Liquid Plastics to create castings with varying looks and densities.

Effect of 15X Addition on Pot-Life and Demold Times

% 15X PrePot-Life Demold Time Shore D Mixed with B (1-lb Mass) (-in casting) @ Demold 0.00 0.10 0.25 0.50 26 min 8 min 3 min 1.75 min 225 min 16 min 8 min 6 min 45-55 38-55 38-55 38-55 Shore D @ 24 hr 76 76 76 76

Casting Plastics

Note on Spraying Poly 1512X Plastic

Poly 1512X accelerated with Poly 74/75 Part X can be sprayed using low cost spray equipment, such as Plas-Pak guns, or more sophisticated spray systems. The amount of 74/75 X required varies depending on temperature. Adding 1.35 g of 74/75 Part X to 1 lb of 1512X Part B yields a 10 second working time sprayable plastic. Experiment to determine the amount of 74/75 X needed. Only spray in well ventilated areas such as a spray booth. For more information on Plas-Pak spray equipment, see p. 64.

Mother Earth Float in Macys 74th Annual Thanksgiving Day Parade was hard-coated with Poly 1512X Liquid Plastic to create a tough, paintable surface. The float, sponsored by Maytag Neptune Washer, was built at Macys Parade Studio.

15 Series Product
Unit Sizes (lb) Poly 15-3, 15-3X Mix Ratio 1A:1B 5.0 20.0 100 4.0 16.0 80.0 900 3.2 12.0 48.5

Packaging
Part A (lb) 1 qt (2.5) 1 gal (10) 5 gal (50) 1 qt (2.0) 1 gal (8.0) 5 gal (40.0) 55 gal (450) 1 pt (0.7) 1 qt (2.5) 1 gal (10.0) Part B (lb) 1 qt (2.5) 1 gal (10) 5 gal (50) 1 qt (2.0) 1 gal (8.0) 5 gal (40.0) 11 x 5 gal (450) 55 gal (450) 1510 only! 1 qt (2.5) 1 gal (9.6) 5 gal (38.0) (610)559-8620 (800)858-5990

Poly 15-6, 1510, 1511, 1512, 1512X Mix Ratio 1A:1B

Poly 15-8 Mix Ratio 26A:100B

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Casting Plastics/Resins

Poly-Optic 14 Series Clear Casting Resins

DESCRIPTION: Poly-Optic 14 Series Casting Resins are twocomponent, polyurethane systems that were formulated specifically for applications where optical clarity is a must. Use Poly-Optic plastics for casting decorative objects, production parts, models and more. Castings are clear like water; however, PolyColor dyes can be added to obtain clear, colored castings. Poly-Optic systems, with their low viscosities and long pot-lives, provide for easy mixing, excellent detail penetration and easy degassing resulting in bubble-free castings when vacuum or pressure casting techniques are employed. Poly-Optic 1410 cures to a hard plastic that is virtually unbreakable. Cure 1410 at room temperature and, for optimum physical properties, post cure at 150F. Poly-Optic 1411 is an easy 1A:1B, by volume system that cures quickly to a super-strong, hard plastic. Poly-Optic 1411 develops hardness and can be demolded more quickly than 1410. It also has a higher heat deflection temperature, which is useful in certain prototyping applications.

FEATURES
Crystal clear, like water Low viscosity for easy pouring Reproduces fine detail Can be machined, drilled and sanded Long working time Low shrinkage upon cure

MIXING: See p. 46 for information on proper mixing. VACUUM DEGASSING OR PRESSURE CASTING: For bubble-free Poly-Optic castings, vacuum degassing or pressure casting must be employed. See page 16 for more information on vacuum and pressure. A light spray of Pol-Ease 2300 or quickly passing the flame of a torch over the back of the casting helps break any bubbles on the back of the pour. Casting Plastics 51 CURING: Poly-Optic 1410, 1411 and 14-70 cure at room temperature. For castings less than 0.25-inch thick, 1411 is recommended because it can be demolded more quickly in thin sections. For thinner castings, or when using Poly-Optic 1410 for thin parts, add Part 14X Catalyst or heat cure (8 hr at 140-150F). Castings greater than 0.5-in thick do not require heat or 14X, but the addition or use of either will speed up the curing process considerably. Poly-Optic 1420 cures in 8 hours at 150F, or 16 hours for optimum physical properties. If cured at a higher temperatures, parts may be demolded sooner (e.g., 30 min at 180F depending on size. For brittle, glass-like parts, cure 1420 at room temperature. Wash mold release from surfaces prior to painting or bonding. ACCELERATING CURE SPEED: Mix Poly-Optic 14X Catalyst into Part B prior to adding Part A to accelerate the gel and cure time for Poly-Optic resins. 14X is recommended for castings less than 0.5-in thick. For best results, mix Parts A and B, degas if required, then add 14X and degas again if necessary. Adding 0.5% 14X to the total mix weight speeds the cure significantly. For example, 0.5g 14X in a 100g mix of Poly-Optic 1410 halves the

Poly-Optic 1420 cures to a tough, impact- and heat-resistant plastic that can be polished and machined. For strong plastic, heat cure 1420 at 150-180F. For brittle, glass-like castings, cure at room temperature. Poly-Optic 14-70 is a firm rubber. Blend 1410 and 14-70 to achieve any hardness between Shore D85 and Shore A70. (See table on next page.) MOLD PREPARATION: Poly-Optic products reproduce minute detail from a mold or pattern but may stick or foam when poured on improperly prepared surfaces. A trial casting on a surface finish similar to the final mold should be made to avoid damaging a valuable mold. Polyethylene and silicone rubber molds, such as PlatSil 71and 73 Series products, do not require a release agent. [CAUTION: Condensation-cure silicones (i.e., TinSil 70 Series) are not recommended for casting Poly-Optic since residual alcohol may inhibit the cure or result in hazy castings.] Latex, polyurethane or metal molds must be dry and require a coat of a suitable release agent, such as Pol-Ease 2300 Release Agent. For optically clear castings, use highly polished masters to create molds with excellent surface quality.

PHYSICAL PROPERTIES
Poly-Optic Product Mix Ratio Hardness (Shore A or D) Pour time (min), 2-lb mix Maximum exotherm, 2-lb mass Demold time (hr)* Specific gravity Viscosity, 2 min after mixed (cP) Specific Volume, in3/lb * 1410 3A:2B, by weight D80 15 265F (129C) 2 (1-in thick)* 1.07 700 27.5 1411 1A:1B, by volume D80 9 228F (109C) 0.5 (.5-in thick) 1.07 600 27.5 1420 2A:1B, by weight D85 15 311F (155C) 8 @150F/0.5 @175F 1.05 250 27.5 14-70 4A:5B, by weight A70 15 190F (88C) 24-48 1.06 340 27.5

Demold time varies with thickness of casting and the amount of Part 14X Catalyst added.

www.polytek.com

Casting Plastics/Resins
PACKAGING
Product Poly-Optic 1410 Mix Ratio 3A:2B Poly-Optic 1411 Mix Ratio 1A:1B (By Volume)

pour and cure time. Exotherm (heat of reaction; see p. 6) and thus shrinkage on cooling is also increased. Experiment to determine the best amount of 14X to use, but do not use more than 1% 14X because final physical properties may be affected. RETARDING CURE SPEED: Poly-Optic 14R Retarder slows the cure of Poly-Optic systems. Slowing the cure also reduces exothermic heating that can cause distortion, waviness and shrinkage especially in castings >0.5-inch thick. Add 1.5% 14R to the total mix weight of Poly-Optic 1410 to increase pot-life from 15 minutes to 70 minutes. Add 1% 14R to 1411 to double the working time from 9 to 18 minutes. Depending on the size and mass of the part, post curing Poly-Optic 14-70 and 1410 parts in the mold at a minimum of 140F for 12 to 16 hours may be necessary. The extended pot-life creates a lower exotherm upon curing, allowing larger castings to be made without distortion. Never use more than 4% since the system may not cure properly. See table to right regarding 14R addition to 1410. COLORS: Add PolyColors (see p. 61) to 14 Series Part B before mixing with Part A to create clear plastics of any color. EXTERIOR USES: Although Poly-Optic 1410, 1411 and 1420 are non-yellowing formulas, they are not recommended for longterm exterior use. Poly UV Additive can be added to improve durability for exterior applications. Add 1% UV Additive to the total mix weight of Poly-Optic to reduce the onset of chalking and pitting of the outside surface for ~2 years. Add 3% Poly UV Additive to achieve good exterior stability beyond 5 years. CLEAN UP: See p. 47. SAFETY: See p. 47. STORAGE LIFE: Poly-Optic liquids can be stored for at least 6 months in unopened containers stored at room temperature. PolyOptic Part As may crystallize slightly or become viscous during storage. If crystallization occurs warm the container to 100-120F until crystals dissipate. Cool to room temperature before use.

Unit Weight (lb) 10.0 60.0 3.8 15.2 76.0 6.0 24.0 120.0 14.4 72.0

Poly-Optic 1420 Mix Ratio 2A:1B

Poly-Optic 14-70 Mix Ratio 4A:5B

Poly-Optic 1410 Gel Times with 14R Addition

Weigh, add and mix 14R into 1410B. Weigh and add 1410A, plus one additional part A for every part of 14R used in the 14R/1410B premix. Mix well. Pour into prepared mold. Degas or pressure cast for bubble-free castings. 1410Part A 1410Part B 14R Gel Time (min) 100 66.6 0 15 100.5 66.6 0.5 21 101 66.6 1.0 40 101.5 66.6 1.5 72

Casting Plastics

Blending Poly-Optic 1410 and 14-70* for Various Hardnesses

1410 Part A 100 100 100 100 100

The clarity of Poly-Optic 1410 is remarkable. This amazing negative sculpture comes to life with overhead lighting.

1410 Part B

52

42

33

23

13

14-70 Part B Shore A Hardness Poly-Optic 1410 Liquid Plastic was poured into a cylindrical mold to form a rod, which was softened in hot water and coiled around a mandrel. Once cooled, it holds its shape to form a tough, spring-like coil. Shore D Hardness

25

44

62

82

100

NA

NA

95

88

75

87

77

60

37

25

* Note: Premix Poly-Optic 1410 and 14-70 Part Bs prior to mixing with Part A. Poly-Optic 1410 and 14-70 Part As are the same; therefore, premixing Part As is not necessary.

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Casting Plastics/Resins

PolyFoam Series Casting Foams

DESCRIPTION: PolyFoam Series Casting Foams consist of liquid Parts A and B that, after mixing, form self-skinning foams. PolyFoam can be used to cast rigid or flexible objects with densities in the range of 3-20 lb/ft3. Considered PolyFoam for production of decorative objects, lightweight mold shells, production parts, tools, models, patterns, fixtures, duplicate masters and general tooling use. PolyFoam systems do not contain toluene diisocyanate, MOCA, heavy metals or HCFCs, and are practically odorless. PolyFoam R-2, R-5 and R-8 are rigid foams. PolyFoam F-5 is flexible for casting soft parts. MOLD PREPARATION: See p. 46. Be sure that rubber molds used with PolyFoam are stiff enough so as not to distort when subjected to packing pressures. Use a suitable barrier coat such as Barrier PF to extend mold life when using rigid foams. If Barrier PF is used, apply Pol-Ease PF Release Agent to the mold prior to applying Barrier PF. MIXING: See p. 46 for general guidelines. Combine Parts A and B and mix immediately with a Turbo mixer or other high speed mixer for 30 seconds. Pour mix into cavity as quickly as possible since foaming starts immediately. If too much time elapses, the foam will rise in the mixing container and the mix may be lost. Once containers of Parts A and B are opened, they should be used or resealed tightly as atmospheric moisture contamination may degrade product integrity causing excess foaming, pressure build up and poor cure properties. To improve shelf stability of the liquid products, use Poly Purge to displace moist air in opened A and B containers before resealing. CURING: Packing PolyFoams to a minimum of 2-3 lb/ft3 above their free-rise density is recommended to achieve good surface detail and mold fill. A lid with small vents to allow air to escape as foam rises should be firmly clamped in place prior to rise. Once foam begins rising, avoid stirring or other movement that will cause cells to collapse. Castings should be allowed to remain in the mold until thoroughly cured. Parts demolded too soon may be subject to deformation. For best casting results, the mold should be warmed to between 75F and 85F prior to casting the first part. Once a mold is heated and cycled, it will maintain heat for continued production. FINISHING: See p. 47 for general guidelines. When casting rigid foams, the use of an appropriate primer/barrier coat, such as

FEATURES
Easy 1:1 mix ratios Self-skinning foams Rigid and flexible foams Densities range from 3 to 20 lb/ft3

POLYFOAM PHYSICAL PROPERTIES R-2 Mix Ratio (By Weight or Volume) Mix Viscosity (cP) Cream Time (sec) Rise Time (min) Tack-Free Time (min) Demold Time (min) Free-Rise Density (lb/ft3) Molded Density (lb/ft3) 1A:1B 500 30 3 10 30 2.5 4-8 R-5/R-8 1A:1B 1100 45 2 3 10-15 5 (R-5) 8 (R-8) 8-20 F-5 1A:1B 1400 45

25 30-60 5 8-15

Note on PolyFoam Compaction Calculation:

Using the desired density or compaction in pounds per cubic foot (lb/ft3), divide that number by 1728 cubic inches (in3). The result will be a decimal factor (0.004576 or similar). Then multiply the volume of the space you want to fill with foam (in in3) by the factor. The result equals the pounds of PolyFoam liquid to prepare.

Barrier PF, sprayed and allowed to dry in the mold before casting will result in a pre-primed part upon demolding. CLEAN UP & SAFETY: See p. 47.

POLYFOAM PACKAGING
Components Unit Weight (lb) Part A (lb) 4.0 16.0 80.0 900 1 qt (2.0) 1 gal (8.0) 5 gal (40.0) 55 gal (450) Part B (lb) 1 qt (2.0) 1 gal (8.0) 5 gal (40.0) 55 gal (450)

PolyFoam R-2, R-5, R-8 and F-5 Mix Ratio 1A:1B (By Weight or Volume)

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Casting Plastics

3-5

Casting Plastics/Resins

Poly LiteCast Liquid Plastic

DESCRIPTION: Poly LiteCast Liquid Plastic has a wood-like density and can be used to produce decorative objects, tools, models, patterns, fixtures and duplicate masters. Poly LiteCast reproduces fine details from molds and can be drilled, sanded and machined. MOLD PREPARATION: See p. 46. MIXING AND CURING: See p. 46. [Note: Stir both Parts A and B before use since the filler in Poly LiteCast rises to the top.] ADDITIVES: To accelerate the cure, add Part 15X Catalyst. A few drops of Part 15X added to one-pound of mixed Parts A and B speeds the cure significantly. When using Part 15X, exotherm (heat of reaction) increases and can result in shrinkage of the cast part. Experiment to determine the right amount of Part 15X to use but never use more than 1% of the total weight of the mix or the final physical properties may be affected. If a paste-like consistency is needed for brush-on or trowel application, add Poly Fiber or Cab-O-Sil to thicken the mix. Casting Plastics PolyColors (see p. 61) can be added LiteCast Part B before mixing with Part A to create plastic of any color. CLEAN UP: See p. 47. SAFETY: See p. 47. FEATURES Wood-like density Easy 1:1 mix ratio by weight or volume Safe and easy to machine, contains no silica Tough and hard, but not brittle PHYSICAL PROPERTIES
Mix Ratio, By Weight or Volume Hardness, Shore D Pour Time, 1 lb. mix (min) Demold Time (hr) (varies with 15X) Viscosity, 2 min after mix (cP) Specific Volume (in3/lb) 1A:1B 55 5 1 2,480 35

PACKAGING
Unit Weight (lb) A 3 12 60 1 qt 1 gal 5 gal Size B 1 qt 1 gal 5 gal Containers Net Weight (lb) A 1.5 6.0 30.0 B 1.5 6.0 30.0

Poly Plasti-Flex Liquid Plastic

DESCRIPTION: Poly Plasti-Flex Liquid Plastic is flexible making it ideal for casting decorative trim and molding that needs to be mounted on a curved or uneven surface. Plasti-Flex can also be used to make special effects castings and props and impactresistant forms, tools and parts. Plasti-Flex has a wood-like density and can be drilled, sanded, nailed and screwed. MOLD PREPARATION: See p. 46. MIXING AND CURING: See p. 46. ADDITIVES: PolyColors (see p. 61) can be added Poly PlastiFlex Part B before mixing with Part A to create plastic of any color. CLEAN UP & SAFETY: See p. 47. PHYSICAL PROPERTIES
Mix Ratio, By Weight or Volume Hardness, Shore A Pour Time, 1 lb. mix (min) Demold Time (min) Viscosity, 2 min after mix (cP) Specific Volume(in3/lb) 35A:100B 90 3 ~15 3,000 34 Poly Plasti-Flex architectural trim casting. The casting, which is held in a curved position, can be easily mounted on a curved surface.

FEATURES FLEXIBLE! Wood-like density Safe and easy to machine, drill or sand (no silica)

PACKAGING
Unit Weight (lb) A 8.1 38.5 192.5 1 qt 1 gal 5 gal Size B 1 gal 5 gal 5 x 5 gal Containers Net Weight (lb) A 2.1 10.0 50.0 B 6.0 28.5 142.5

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Casting Plastics/Resins

Polygel Liquid Plastics

U.S. Patent # 5,128,433 DESCRIPTION: Polygel Plastics produce strong, light-weight mold shells and are ideal for shells built up with a brush or spatula on vertical or overhead surfaces. Sprayable Polygel Shell is ideal for large surface area applications where brushing may be impractical. Polygel products consist of liquid Parts A and B, that after mixing 1:1 by weight or volume, immediately self-thicken. MIXING & CURING: See p. 46 for general guidelines. For Polygel Plastic-75, mixing of Parts A and B should be rapid and thorough. Most mixing should be completed within ten seconds or so before gelling begins and while the mix is still liquid to minimize air entrapment. Mix only enough that can be applied during the working time. Polygel Plastic-75 generates heat when mixed, so use rubberized cotton gloves to ease handling of the hot container. Once mixed, dumping the thickened mix on the surface to be coated and quickly spreading into a thin layer will cool the mass and extend working time by a minute or two. Do not try to demold Polygel Plastic-75 until adequate cure time has elapsed as it may be somewhat brittle. Polygel Shell Plastic is a rapid-setting liquid plastic designed for spray applications. Hand mixing is not recommended. When meter-mixed and sprayed 1:1 by volume, Polygel Shell gels several seconds after contacting the surface being covered, then remains in a workable grease-like state for 1 minute. Shells or castings can be demolded in 2 hours depending upon thickness and ambient temperature. Thicknesses <-inch may require longer cure time. Thin, tough coatings can be applied to many surfaces such as carved foam. Mold shells should be approximately -inch thick. When spraying a mold shell, thicknesses >-inch are not recommended as shrinkage can occur upon curing and cooling. For additional strength, lay fiberglass strand or mat while applying Polygel Shell. For very large shell sections, supporting structures such as boards or metal rods can be attached to prevent warping or damage during use. STORAGE: In order to maintain dimensions, Poly Plastic mold shells must be stored in temperatures <100F. Also, the shells must not be distorted in storage (e.g., no heavy objects placed on top). See p. 47. CLEAN UP & SAFETY: See p. 47. FEATURES Easy -- 1:1 mix by weight or volume Fast -- same-day mold shells Strong and lightweight Color-coded mix indication Long life for molds and shells

The photo below shows the brushed Polygel 35 mold supported by its thin, lightweight Polygel Plastic-75 shell. The hollow, rotocast part was cast using EasyFlo 120 and swirled PolyColor dye to achieve a marbled appearance.

PACKAGING Mix Ratio 1A:1B (by weight or volume) Unit Weight (lb) 4 16 80 900 80 55

Polygel Plastic-75

Polygel Shell

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Casting Plastics

This photo shows Polygel Plastic-75 being applied with a spatula over a Polygel 35 rubber mold to create a rigid plastic mold shell. Notice that the uncured plastic is thixotropic -- it can be moved around the mold surface but does not drip or sag.

Casting Plastics/Resins

Polypoxy Resins

DESCRIPTION: Polypoxy Resins and Poly Cure Hardeners are liquids that, after mixing in proper ratio, cure at room temperature to high-strength plastics. Resins can be cured with various curatives enabling users to select the best system for a particular use. The mix ratio for each curing agent and resin blend varies. For best results, carefully weigh the components. Polypoxy 1010 is a clear resin for use with fast Poly Cure 1212 for small castings such as bonded bronze or with fiberglass or fillers for lay-up and mother molds. Use with Poly Cure 1220 for decoupage clear coatings, glass bonding and many other uses where a nearly colorless, clear, low viscosity resin is required. Polypoxy 1030 is an aluminum- and mineral-filled resin for lay-up or small castings when cured with Poly Cure 1212. For larger vacuum forming molds and other tooling uses, cure with Poly Cure 1230. Parts made with Polypoxy 1030 can be machined, drilled and burnished with steel wool to a pewter finish. SURFACE PREPARATION: Polypoxy Resins are adhesives and bond to many surfaces. If adhesion is not desired, surfaces must be made non-porous with a suitable sealer, such as wax, PVA, lacquer or other coatings. The surfaces must then be coated with a release agent such as Pol-Ease 2300. Poly 74 Series rubber molds require only a light, thorough coating of Pol-Ease 2300 for excellent release of epoxy castings. Perform a small test cure. MIXING: Polypoxy and Poly Cure must be mixed in the ratios shown below. Mix ratios are by weight except for Polypoxy 1010 and Cure 1220, which can be mixed 1:1 by volume. Polypoxy and Cure must be thoroughly mixed and poured as soon as possible after mixing to ensure low viscosity and good flow. Watch a clock to avoid being caught with unused, cured material. HEAT RESISTANT CASTINGS: Polypoxy 1030 offers good heat resistance. Call Polytek for more information. CLEAN UP: See p. 47. SAFETY: Before use, read product labels and Material Safety Data Sheets. Follow safety precautions and directions. Poly Cure Hardeners cause severe eye and skin burns. Do not get in eyes or on skin. WARNING: The epoxy cure reaction is very exothermic (see p. 6). Do not cast large masses -- doing so can result in a fire!

APPLICATIONS
Polypoxy 1010 + Poly Cure 1212 Bonded bronze Polypoxy 1010 + Poly Cure 1220 Decoupage coatings and glass bonding Polypoxy 1030 + Poly Cure 1212 Small castings and tooling applications Polypoxy 1030 + Poly Cure 1230 Larger vacuum molds

PACKAGING
Product Polypoxy 1010 Unit Weight (lb) 2.0 9.0 45.0 3.0 12.0 60.0 0.25 2.0 0.25 2.0 8.0 40.0 0.25 2.0 8.0 Container 1 qt 1 gal 5 gal 1 qt 1 gal 5 gal 4 oz 1 qt 4 oz 1 qt 1 gal 6 gal 4 oz 1 qt 1 gal

Casting Plastics

Polypoxy 1030

Poly Cure1212 Poly Cure 1220

Poly Cure 1230

PHYSICAL PROPERTIES
Polypoxy + Poly Cure Parts Cure per 100 of Polypoxy Mixed Viscosity(cP) Pour Time, 150 g mix @ 77F (min) Demold Time @ 77F (hr) Maximum Casting Thickness (in) Shore D Hardness Specific Gravity Specific Volume (in3/lb) Density (lb/in3) 1010 + 1212 15 3,000 25 48 0.5 95 1.13 24.5 0.0408 1010 + 1220 85 (1:1 by vol) 3,000 30 48 1.5 80 1.07 26.0 0.0386 1030 + 1212 6 10,000 30 24 3.0 98 1.70 16.3 0.0614 1030 + 1230 15 5,000 120 24 8.0 95 1.70 16.3 0.0614

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Speciality Materials

Speciality Mold Making & Casting Materials

This section describes a few speciality mold making and casting materials offered by Polytek. These materials can be used in conjunction with Polyteks traditional mold rubber and casting plastic products, enabling users to tackle virtually any mold making and casting challenge. Latex - Tough, one-part brushable, castable rubbers Wax - Castable, carvable version; skin-safe version, acceptable for body molds Hydrogel - Safe for skin contact for body molds & life casting

Poly Latex 60
DESCRIPTION: Poly Latex 60 is a one-part, brush-on liquid that, after multiple coats, builds up to form a tough rubber blanket mold. Use Poly Latex 60 molds for casting plaster, concrete and limited casting with some resins. Poly Latex 60 has better tear strength than synthetic rubbers and is sometimes preferred for molds that are peeled off the casting like a sock. However, two-part, synthetic rubbers like Polygel products can be brushed on to final thickness in an afternoon and should be considered as a latex alternative (see p. 36). MODEL PREPARATION: The model should be free of oil, grease and dirt. Wood, oil-based clay, stone and glazed ceramics generally do not require any sealer. Plaster, unglazed ceramics, copper containing metals, water clay and cement should be sealed with shellac. Models made of other materials should be patch tested by applying a coat or two of latex to a small area. If the latex turns dark or sticks after drying, a sealer should be applied. Models with sharp edges or points may yield a better mold if the points are dulled slightly by sanding prior to sealing. Firmly mount the model on a suitable base board (i.e., plywood or a sink cutout available from kitchen counter shops). Drill a hole through the base board to allow air to escape from within the model so that trapped air does not cause defects in the mold. APPLYING & CURING: Brush a thin coat of latex on the model. Be careful not to puddle the latex. A gentle stream of air can help to blow latex into the finest detail and break any bubbles. Let each coat dry for 4 to 16 hours in a warm, ventilated room. Drying time depends on temperature and humidity. Warm, dry air is necessary for fast drying. When dry, the latex loses its milky appearance, and becomes slightly transparent and amber in color. Apply the next coat as soon as the first coat is dry. Apply 6 to 30 coats depending on the desired mold thickness. Molds are typically 1/16- to 1/8-inch thick. For large, flat models, apply latex in a checkerboard pattern, alternating squares between coats. Since there is some shrinkage on drying, the patchwork method reduces stress and warping of the latex as it dries. Latex can be thickened with ground cork, sawdust or Cab-O-Sil in order to fill undercuts. Thickeners must be completely wet out with latex and applied to the outside surface of the mold. The thickened latex must be allowed to dry completely as wet spots trapped in the latex can cause delamination of the mold. If needed, reinforce latex molds by placing fabric (e.g., muslin, burlap, polyester) into a coat of wet latex and then saturate with latex. Allow the fabric coat to dry completely before applying more latex.
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FEATURES Brush-on liquid Great for casting highly ornamental plaster and concrete One part, no mixing or weighing needed Tougher than any other mold rubber

For spray application with a cup gun, mix 1 part Poly Latex 60 with 1 part Poly Latex N. Poly Latex N is available in the same package sizes as Poly Latex 60. Before removing from the model, the latex must be thoroughly dry or heat cured. Heat in a warm oven at 110-150F for 6 to 8 hours to ensure a complete cure. If heat curing is not feasible, place the mold in a warm area for a week to strengthen the rubber. Clean up wet latex with soap and water. Dried latex can be softened with waterless hand cleaner and washed away. USING THE MOLD: Avoid exposing the mold to oils, grease or solvents. Molds can be washed with soap and water. Before casting plaster or cement, wet the mold with a 1% solution of detergent in water to aid air bubble release from the mold surface. Usually, no other release is necessary. For resin casting, a release agent such as Pol-Ease 2300 or PVA is needed. Most resins shorten the life of a latex mold -- Polygel or Poly-Sil rubber molds may last longer. SAFETY: Before use, read product label and Material Safety Data Sheet. WARNING! Latex products contain ammonia and causes eye and skin irritation. Avoid skin and eye contact. Use with adequate ventilation. In case of contact, flush eyes with plenty of water for 15 minutes and seek medical attention. Remove from skin and clothing with soap and water. STORAGE LIFE: At least 3 months in unopened containers stored at room temperature (50-70F). Tightly reseal opened containers. As latex ages beyond 3 months, it will not cure to as supple a rubber and shrinkage on drying may increase and toughness of the mold will decrease. Exposure to temperatures below 40F and above 80F may damage latex, causing irreversible coagulation. DO NOT ALLOW TO FREEZE. PACKAGING
Unit Weight (lb) 2.0 8.0 40.0 400 Container 1 qt 1 gal 5 gal 55 gal

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Speciality Materials

Speciality Materials

Poly Latex False Face Compound

DESCRIPTION: Poly Latex False Face Compound is a one-part pourable liquid that, when poured into a dry, unsealed gypsum mold, cures to a high-strength, flexible casting rubber. False Face was formulated to produce flexible hollow parts for uses such as novelty masks, flexible sculpture and animatronic applications. MODEL PREPARATION: To cure properly, this product must be cast into dry, unsealed, porous plaster molds. The user must determine the suitability of other porous mold materials. MIXING AND CURING: Shake or stir Latex False Face before use. Pour into a prepared gypsum mold. Tilting or lightly vibrating the mold may help eliminate bubbles if the mold contains complex undercuts or deep details. For a thin skin, pour the excess latex back into the container immediately. For a thicker skin, allow the latex to stay in the mold longer before pouring off excess. A standing time of 15 minutes yields a 3/32-inch thickness in a dry No. 1 Pottery Plaster mold. Denser plasters are not as
Latex False Face molds can be made by dipping a dry, porous plaster model into False Face. The longer the model is submerged, the thicker the mold. This technique is only suitable for models with a shape that wont trap air when placed upside down in the False Face liquid.

FEATURES Easy one-part rubberno mixing or weighing Tougher than any other mold rubber Good reproduction of fine detail Forms hollow castings without roto-molding

absorbent and thicknesses build slower. Allow False Face to dry in the mold for 24 hours at room temperature. Elevated temperatures accelerate drying time. Clean up wet latex with soap and water. Dried latex can be softened with waterless hand cleaner and washed away. USING THE CASTING: Lightly dust the inside of the casting with talc in order to prevent the dry rubber from sticking to itself. Avoid exposing the casting to oils, greases or solvents. Castings should be stored out of direct sunlight. SAFETY & STORAGE: Same as Poly Latex 60 (see p. 57). PACKAGING
Unit Weight 2.0 8.0 40.0 Container 1 qt 1 gal 5 gal

Poly Wax 15
Speciality Materials DESCRIPTION: Poly Wax 15 is a white, hard, low shrinkage, mineral-filled wax, which can be cast and carved. When cast, it replicates the mold surface in detail and finish. Tool cuts are smooth and lustrous. Dull surfaces can be hand polished with a soft cloth to a satin luster. MELTING AND CASTING: Poly Wax 15 softens below 130F and is quite fluid at 160F. Viscosity decreases rapidly as temperature is increased. At 200F, components of the wax separate slightly. Mix the melted wax thoroughly before pouring. Complete mixing is quick and easy to determine visually -- mixed liquid wax is uniformly colored with no streaks. Use a nonporous, heat resistant stirrer such as a metal spatula. Pour temperatures are typically 210F-280F; however, the ideal temperature is dependent on the mold size, shape and material. Poly Wax 15 holds temperature for a long time, so large or multiple molds can be filled in a single pour. When slush molding, excessively high temperatures will cause remelting of layers already laid down and PHYSICAL PROPERTIES
Softening point Use temperature Viscosity @ 100C (212F) @ 25C (77F) Density (in3/lb) @ 100C (212F) 126F 210 - 280F 116 cP 19.5 21.6

FEATURES Ideal for prototypes Cast carving blanks from rubber molds of rough originals Suitable for master models Smooth and lustrous surfaces significantly prolong the procedure. Casting temperatures that are too low will result in surface bubbles and knit marks because the wax solidifies too rapidly on the mold surface. Poly Wax 15 can be poured in Poly 74 Series, Poly-Fast 72-40, Poly-Sil, Polygel or Hydrogel molds. Latex will be softened by continual pours of Poly Wax 15. Most heat resistant resins and metal molds are also suitable; however, a small trial casting is always recommended to be sure castings release satisfactorily and do not damage the mold material. SAFETY: Before use, read product labels and Material Safety Safety Sheets. Hot wax can cause severe burns and ignites easily. Avoid skin contact. Do not heat with an open flame. Do not heat above 280F since vapors can ignite. STORAGE LIFE: At least 12 months from date of shipment. PACKAGING
Poly Wax 15 is available in 5-lb blocks (610)559-8620 (800)858-5990

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Speciality Materials

Poly Skin-Wax
DESCRIPTION: Poly Skin-Wax is a liquid at temperatures as low as 125F and it is somewhat elastic after solidifying. It can be applied to models using dip or brush-on techniques. Poly SkinWax has been formulated with non-toxic materials and is safe for skin contact provided temperature is carefully controlled. MODEL PREPARATION: When making a mold of a body part, coat skin and hair with baby oil before applying Skin-Wax. Molds can only be made of body parts that are covered with short and light hair -- do NOT attempt to make molds from hairy areas. For most other non-porous models, Poly Skin-Wax is self releasing and, therefore, no release agent is needed. Make a small test mold on a surface identical to the model to determine that release properties and hardening of Skin-Wax is suitable. PROCEDURE: Use a therapeutic paraffin bath, available from medical supply stores, to melt Poly Skin-Wax. A crock pot can be used to melt Skin-Wax; however, extreme caution must be exercised to ensure that the wax is not overheated. To melt Poly SkinWax, heat to 160-180F. Skin-Wax must be cooled to 125-135F before contact with skin! Even this temperature may cause discomfort in some individuals. Do not use Skin-Wax on sensitive areas such as the face. The wax must be just hot enough to produce good results; a few degrees hotter can cause considerable discomfort. Test judiciously on small areas. Stir Skin-Wax often during melting and use since temperature variations in an unstirred bath can result in solidified wax in one area of the bath while another area heats enough to cause burns. Monitor temperature in several places in the bath (i.e., near walls, center and at several depths). Use an accurate thermometer. Apply Skin-Wax by dipping the model, brushing on or slowly pouring over the model surface. For rapid cooling, immerse the wax-coated model in cool water between coats. Skin-Wax can be reinforced by laying fabric such as cheese cloth onto the previous coat and then applying wax to saturate the fabric. Although some flexibility remains in Poly Skin-Wax at room temperature, if flexibility is needed to remove the model, it is best to remove it as soon as the wax cools into the elastic (temporarily deformable) state. For model shapes that do not allow removal with the mold intact, the mold may be carefully cut and later rejoined using a warm metal spatula or by welding with molten wax. Small air vents punctured in the mold using a pin or wire may help release the mold from the model; for example, in casting a hand, pinholes at the end of each finger facilitate removal of the hand. Holes can be sealed later with a dab of molten wax. PHYSICAL PROPERTIES
Softening Temperature Use Temperature Viscosity @ 180F Specific Volume (in /lb)
3

FEATURES Safe for skin contact One-part mold making compound No mixing -- simply melt and use Fast -- make a mold in 5 to 10 minutes Easily repaired with a dab of warm wax Flexible when warm Self releasing from most surfaces Reusable

SAFETY: Before use, read product labels and Material Safety Safety Sheets. Follow safety precautions and directions. Do not heat with open flame. Do not heat above 280F since vapors can ignite. Use with adequate ventilation. Do not use in the presence of sparks or open flame. Exercise extreme caution when applying Poly Skin-Wax to the skin. While Poly Skin-Wax is safe for skin contact, it is not recommended that repeated castings be made over a short period as the hot wax tends to remove skin oils and can cause irritation. For skin applications, avoid reusing wax that may have absorbed irritating substances from casting materials. STORAGE LIFE: At least 12 months from date of shipment. PACKAGING
Poly Skin-Wax is available in 5-lb blocks

125F 125-180F 190 cP @ 77F @ 180F 31 34

The hand is dipped into melted Poly Skin-Wax (125F) then into cold water to harden the wax. Over the next few minutes the process is repeated 2 or 3 times to buildup mold thickness. After the wax is hardened, the mold is slipped off the hand and is ready for casting. Plaster, cement, rubber or plastic can be poured into the hand mold. Be careful not to use a casting material that generates significant heat upon cure. The wax is removed from the casting and can be melted for reuse. That casting is detailed -fingerprints and all!

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Speciality Materials

Speciality Materials

Hydrogel N Mold Compound

DESCRIPTION: Hydrogel N is a white powder that after mixing with water cures in about 5 minutes to a moist, rubbery material. Use Hydrogel N to make quick, single-use molds, especially when skin contact is required. Plaster, wax, and certain EasyFlo Plastics can be cast into Hydrogel N molds. MODEL PREPARATION: Hydrogel N can be poured on most surfaces with minimal preparation, but perform a small test cure to be sure that Hydrogel N releases cleanly and does not damage water sensitive surfaces. Use a thin coat of petroleum jelly or Pol Ease 2300 Release Agent to seal questionable surfaces. MIXING AND CURING: Weigh or measure proper amounts of Hydrogel N powder and room temperature water. The mix ratio is 3 parts water to 1 part Hydrogel N, by weight, or approximately 1 water to 1 Hydrogel N, by volume. Mix together rapidly to a creamy consistency, but avoid whipping in air. For best results, use a Turbo Mixer (see p. 62) on a variable speed drill. Add powder or water as needed to thicken or thin the mix. Working time is about 5 minutes, but can be extended using Retarder Solution (see table below). Apply the creamy mix to the model surface with a flowing motion, pushing air ahead of the mix. Demold with care 2 to 3 minutes after the mix has gelled. To make a large blanket mold, make and apply a series of mixes within 5 minutes of one another. Hydrogel N bonds to itself if the previous mix is not completely gelled. To help a new mix bond to already gelled Hydrogel N, wipe the gelled material with a saturated solution of water and baking soda (sodium bicarbonate). Add food color to the bonding solution so that you know where it has been applied. Continue layering Hydrogel N as needed to make a ~3/8-inch-thick blanket mold. In the final layer of wet Hydrogel N, press teased cotton (cotton rolls, available at any pharmacy) evenly over the entire mold surface and allow to gel. Remove excess cotton by pulling gently, leaving a thin layer of exposed fibers. As soon as Hydrogel N is firm, mix and apply a plaster mold shell using bandages, cheesecloth, or hemp embedded in the plaster. The exposed cotton fibers in the mold will bond to the plaster shell helping to keep the mold attached. When the

FEATURES Non-toxic-- Safe for body casts Easy to use: just add water and mix Good reproduction of fine detail Early strength for fast demold Variable working time Low cost
Hands up and on the table! With the use of HydrogelN, these children each made a plaster cast of their own hand at a Vacation Bible School craft session. Molds for 35 hands were made in less than 2 hours!

plaster shell is set, remove the Hydrogel N mold/plaster shell. For best dimensional stability, make a positive casting immediately. USING THE MOLD: Plaster or waxes below 212F may be poured in Hydrogel N molds. For best results use the mold when it is as fresh as possible, since Hydrogel N molds shrink as they dry. Molds can be kept useable in plastic bags or sealed containers for up to a few days. Molds should then be discarded SAFETY: Before use, read product label and Material Safety Data Sheet. Follow safety precautions and directions. Handle Hydrogel N carefully to avoid dust generation. Wear a dust mask. Avoid eye contact. Hydrogel N is not for human consumption or use against mucous membranes. Keep skin contact as brief as possible. Prior to placing Hydrogel N on hair, hair should be slicked down with petroleum jelly or cholesterol hair conditioning cream. STORAGE LIFE: At least six months in unopened containers. LIQUID RETARDER (OPTIONAL)
% Retarder in Water 0 3 6 9 Approximate Working Time 5 min 7 min 8 min 10 min

Speciality Materials

PACKAGING
Product Hydrogel N Hiram Ball, of Ball Consulting Ltd., demonstrates making a livebody mold using Hydrogel N. The safe-for-skin-contact alginate yields excellent mold impressions if wax or plaster is cast right after demolding.

Volume 1 qt 1 gal 5 gal 1 qt

Retarder Solution

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Accessories

MATERIALS
HEMP - Long, natural fiber that has been the traditional reinforcement for plaster mother molds. Available in convenient 10-lb bundles or economical ~40-lb bales. POLY FIBER II - Add to liquid rubbers to thicken for brush-on application or plastics for mold shells or layup castings. Add to resin (up to 5% total weight) to produce thin gels to thick pastes. (5-gal pail or 10 lb bag) TIETEX FABRIC Strong, conformable reinforcing fabric that wets out very well. Small pieces can be laminated in at the top of a seam in brushed or sprayed molds to prevent tearing. A sheet can be laid into the back of an open poured mold to increase durability. Use as bridging material for spanning undercuts in sprayed or brushed molds. 10-ft sheet (40-in wide) 324-ft roll (40-in wide) FIBERGLASS MAT - Non-woven, 1.5 oz per sq. ft., chopped strand mat for reinforcing Polytek resins. 3 square yards POLYPLASTICENE - Non-hardening, sulfur-free modeling clay. Non-toxic and odorless, with a smooth, firm consistency for sculpting. Also makes great reusable caulk for mold boxes. 1-lb block or 50-lb box. FUMED SILICA/CAB-O-SIL - Add to mixed liquid rubbers and plastics to make thicker and thixotropic mixes for brush-on application. 5-gal pail 10-lb bag Cab-O-Sil is a registered trademark of the Cabot Corp., Tuscola, IL BRONZE POWDER - Use with unfilled resins for "cold-cast bronze." One part bronze powder to one part EasyFlo (by volume) makes beautiful castings! 2-lb can 10-lb can 110-lb can POL-EASE MOLD RINSE - Liquid concentrate reduces surface air bubbles on plaster castings made in Polytek rubber molds. Dip or spray mold with 1 part Pol-Ease Mold Rinse diluted with 10 parts water. Molds should be wet when plaster is poured. 5 gal (40 lb) POL-EASE MOLD DRESSING - Protects and rejuvenates Poly Rubber molds that have been exposed to harsh conditions created by the use of solvents and petroleum oils contained in certain form releases and casting resins. 5 gal (40 lb) or 55 gal (450 lb). POLYCOLORS - NEW! Dyes for coloring Polyteks polyurethane rubbers and plastics. Available in red, blue, green, yellow, brown and black. 0.25-lb bottle or 1.0-lb bottle. UV ADDITIVE - For Improved Exterior Exposure - Thoroughly stir this liquid additive into polyurethane liquid rubber to improve exterior durability; greatly reducing characteristic surface degradation caused by sunlight or other UV light sources. Add 0.5% of the total weight of liquid mix prior to curing. 4-oz bottle or 1-pint bottle (1 lb). POTTERS SOAP - Use to seal plaster models. Plaster should be damp when soaped. Available as a concentrate from Crystal Inc, Philadelphia, PA, (215) 368-1661.

RELEASE AGENTS
POL-EASE 2300 RELEASE AGENT - A blend of silicone oils and resins in a convenient aerosol spray. Pol-Ease 2300 is an effective release for use with most Polytek products. Use a soft brush to distribute evenly. 12-oz can or Case of 12 cans POL-EASE 2500 RELEASE AGENT - An aerosol spray release agent that can be easily washed off cast parts for easy finishing. Spray a thin mist over mold surface, then brush gently for uniform coverage. 12-oz can or Case of 12 cans POL-EASE 2350 RELEASE AGENT - Mineral spirits solution for use with RTV liquid silicone rubbers. Can be brushed or sprayed. Use of a soft brush to spread the release agent evenly to improve results. 1 qt (1.5 lb) or 5 gal (26 lb) POL-EASE 2450 RELEASE AGENT - A fast drying, silicone-based release, which can be brushed or sprayed. Flammable! 1 qt (1.5 lb) or 5 gal (30 lb) POL-EASE 2601 RELEASE AGENT - Water-based emulsion of silicone oils and resins. Spray with the Sure Shot Mini Atomizer for an economical alternative to aerosol release agents. After spraying, distribute evenly with a soft brush. 1 qt, 5 gal (40 lb) or 55 gal (450 lb) POL-EASE 2650 RELEASE AGENT - A high performance, silicone-free, release agent for use in polyurethane molds when casting concrete or plaster. 1 qt (1.5 lb) or 5 gal (35 lb) POLY PVA SOLUTION - Water soluble coating for use as a barrier coat on certain rubber molds (i.e, Poly-Fast 72-40) to allow resins to cure without sticky surfaces. While Poly 74, 70 and 71 Series molds do not cause sticky surfaces on resin castings, PVA may be used as a barrier coat to prevent resin attack on the mold. Can be used as a removable sealer for porous surfaces alone or in conjunction with paste wax. The green film of PVA washes off with water. (Specify Clear or Green) 1 qt (2.0 lb) or 5 gal (35 lb) POLYCOAT - A semi-permanent sealer and release agent that can be sprayed or brushed onto a model when using liquid polyurethanes. In most cases no additional release is needed to demold the polyurethane rubber. 1 qt or 1 gal SURE SHOT MINI ATOMIZER -Use with PolEase 2601, 2350 and 2450 Release Agents. Mini Atomizer (7-oz capacity)

ADHESIVES
POLYPOXY QUICK STICK ADHESIVE - Two-part epoxy adhesive with a 1:1 mix ratio by weight or volume. Bonds quickly to most clean, dry surfaces. Sets in 3-5 minutes. 2-lb kit POLYBOND - A polyurethane adhesive thats great for repairing torn molds. PolyBond has 1A:3B mix ratio (by weight), a ~3 minute working time and a ~15 minute cure. 2-lb kit EPOXYBOND - A low viscosity, epoxy adhesive, which deeply penetrates porous surfaces creating an excellent bond. It has an easy 1A:1B mix ratio (by volume), a long working time (120 min.), and overnight cure. 2-lb kit

www.polytek.com

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MIXING EQUIPMENT
POLY PADDLE The 16-inch Poly Paddle allows complete mixing of material by thoroughly scraping the sides and bottom of rounded or straight sided mixing containers. SPATULAS Top quality, all purpose spatula with a comfortable, cushion-grip, vinyl handle is unbreakable, and heat and chemical resistant. The stainless steel blade is semi-flexible for durability and easy mixing. The mirror finish wipes clean easily. Available in two sizes for most small mixing needs. 4-in Blade Spatula 6-in Blade Spatula JIFFY MIXERS Heavy-duty, efficient, commercial mixer, specially designed for tough-to-mix, viscous materials. Mixes quickly and thoroughly without splashing or whipping air into the mix. The patented protective-ring design prevents puncture or damage to the mixing container. Made entirely of stainless steel 304 for maximum durability. Jiffy mixers fit all - to -inch chucked power tools. Tools with 450-700 rpm give the best mixing results. Jiffy Mixer, 1 gal Jiffy Mixer, 5 gal TURBO MIXERS Ingenious, patented, high efficiency mixers fit any power drill with -inch chuck and mix more efficiently than a Jiffy Mixer. Must be kept free of built up material. Its worth the price! Turbo Mixer, -gal Turbo Mixer, 1-2 gal Turbo Mixer, 3-10 gal Turbo Mixer, 11-55 gal TONGUE DEPRESSORS - Made of straight-grained white birch for consistent quality. Convenient, low cost mixing tools for test cures or small quantity mixes. 6-in length, box of 500

BRUSHES
ACID BRUSHES - Tinhandle, disposable -inch wide brushes with 100% horsehair bristles. Excellent for making small brush-on molds. Bundle of 30 or Box of 1 gross (144) CHINA BRISTLE BRUSHES - Wooden handle chip brushes. 100% China Bristle available in 1inch and 2- inch width. Use to apply brush-on molds or release agent. 1-in Brush, bundle of 10; or 2-in Brush, bundle of 10

SAFETY
NITRILE GLOVES Disposable, powder-free, 4mil nitrile gloves offer comfort, dexterity and a broad range of chemical resistance. These gloves offer protection against intermittent contact with nearly all Polytek products. Contain no natural rubber proteins. 100 per box, Size L SAFETY GLASSES - With a sleek wrap-around polycarbonate lens, Uvex Bandido safety glass offers excellent eye protection, comfort and sporty styling. Meets ANSI Z87.1-1989 Standard. Made in USA. 1 pair (one size) PROTECTIVE COVERALL Kappler NexGen coveralls are made of a micro-porous fabric that is aerosol and liquid proof. Disposable, but durable enough to be reworn. Large size and light weight allows mobility. The perfect cover-up for quick, dirty jobs. Coverall, Size L SOLVENT DISPENSING CAN - Plunger can for dispensing flammable liquid features brass flame arrestor screens and pump assembly. Simply press a cloth or wiper on the plunger to moisten. Two-quart capacity.

MOLD BOX
MOLD BOX Adjustable to any size up to 24-in x 24-in x 6-in. The base is smooth, plastic faced particle board. This mold box provides a quick way to pour a rubber mold. (C-clamps not included.)

MOLD-KEY KNIFE
MOLD-KEY KNIFE - NEW! Use this unique notched knife to cut tongue-and-groove seams in molds. Makes proper mold registration easy.

Accessories

BANDS & STRAPS

RUBBER BANDS - Top quality -inch wide rubber bands made of long lasting, heavy duty natural rubber. Secures mold shell pieces firmly together. 4-in Bands, 1-lb box 8-in Bands, 1-lb box NYLON MESH MOLD STRAPS - One-inch wide nylon straps are adjustable to 8 ft in length. They tighten as the buckle locks to ensure a snug fit. Sold singly or bag of 12

Although we dont offer a full line of safety supplies, well help you get what you need to work safely! Call Polytek and ask for our safety specialist.

PAILS/OPENER
PAILS FOR MIXING - High density polyethylene pails with handles, both 1-gal and 5-gal sizes are now available in cartons. These are the same pails that Polytek uses for its products. They are excellent for mixing Parts A & B and often the cured residue can be stripped out, leaving a clean pail ready for reuse. Lids can be ordered separately. 1-gal Pails (Box of 10) 5-gal Pails (Box of 5) PAIL OPENER - Pail Pal pail opener designed to open and close most plastic pails with ease. Constructed of rugged cast aluminum. (610)559-8620 (800)858-5990

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SCALES
OHAUS CS-2000 PORTABLE SCALE - The ideal scale for users who need a scale in a variety of locations during the work day. Battery operated with an automatic shut-off switch. The CS-2000 has a capacity of 2000 grams (~5 lb) and readability to 1 gram. The digital display reads in grams or pounds and ounces. The scale offers simple operation with a full capacity tare. The CS2000 has an easy-to-clean weighing surface. The AC adapter is sold separately. OHAUS ES50R ELECTRONIC BENCH SCALE This all-purpose, rugged bench scale is equipped with a large, stainless steel weighing pan to withstand heavy industrial use. The ES50R has a 110-lb capacity, a digital display readable to 0.05 lb and a full capacity tare. Can be used with the AC adapter (included) or batteries for portability. An automatic shut-off circuit extends battery life. OHAUS 760-00 TRIPLE-BEAM BALANCE Quality, mechanical balance with readability to 0.1 gram and weighing capacity to 2610 grams (5+ lb) makes this balance more than adequate for weighing small quantities. Weight set included.

DVDS/VIDEOS
Polytek offers DVDs and video tapes to help customers better understand mold making materials and processes. POLYTEK MOLDMAKING DVD Watch step-by-step demonstrations showing how to make a poured block mold; brushed blanket mold with plastic shell; and a poured blanket mold with a plastic shell. See how to use Polytek polyurethane and silicone rubbers and plastics. Only $5.95! POLYTEK BODY CASTING AND SPECIAL EFFECTS SEMINAR/WORKSHOP Body & Face Casting with Hydrogel Alginate, 115 min. BALL CONSULTING LTD. MOLD MAKING AND CASTING A practical how-to video showing the making of a poured mold, a brush-on mold and a poured blanket mold. Casting of Forton MG with a metal powder filled face mix and a glass fiber reinforce back-up. Covers patinas and other finishing techniques. Use of Forton MG to spray-up a large, rigid column mold and rigid carrier molds also shown. Approx. 40-min. SUCCESS WITH FULL BODY MOLDS AND FORTON CASTINGS The definitive video on full-body molding. This Mark Prent video also includes useful information on casting with Forton MG. Approx. 70 min. BETTER ONE-PIECE HEAD MOLDS FROM LIFE Master sculptor Mark Prent takes you step-bystep through every detail of using alginate mold compounds to make head molds of live models (i.e., Hydrogel N). Approx. 75 min. THE USERS GUIDE TO REDUCIT RUBBER MOLDS, AND INNOVATIVE PLASTIC SUPPORT STRUCTURES Mark Prent uses Polytek Mold Rubbers and alginate compounds to reduce a life size sculpture to -scale in two steps. This video offers the solution to an age old problem while maintaining every detail of the original. Approx. 60 min.

BOOKS
METHODS FOR MODERN SCULPTORS By Ronald D. Young & Robert A. Fennell Published in 1980, this is still one of the best general texts on the subject, including a very good chapter on mold making. (292 pp)

POLYTEK CURED SAMPLE STRIPS Two pages of cured sample strips of most Polytek rubbers and resins in a 3-ring binder. A handy reference when selecting a material for a particular job.

ROTATIONAL CASTING
Rotational casting involves rotating a closed mold while a liquid casting material flows over the inner surface of the mold. The liquid clings to the mold surface just enough to create a thin layer of cured material, which creates a hollow casting. Rotational casting is an efficient method of creating large, lightweight pieces such as mannequins and figurines. Fast-setting liquids are used so that pieces can be produced with short cycle times. The 2 machines pictured below are at our PA facility and are available for demos and test runs.

OTHER ACCESSORIES
POLY PURGE DRY GAS BLANKET - Blast Poly Purge into an open container just before resealing the lid to displace moist air and extend the life of polyurethane liquids. Poly Purge is heavier than air and is non-flammable and non-ozone depleting. It is packaged in an aerosol can with a special nozzle extension useful for directing the gas into the desired space. 10-oz can or Case of 12 cans www.polytek.com

Small machines cost ~$5,000 and can support mold loads of ~ 200 lb. Table-top versions are available. Large machines can carry many molds and cost ~ $12,000.

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DRUM HANDLING PRODUCTS

Polytek offers numerous products to make handling drums easier and safer. A few items are shown below. Call Polytek for pricing and details. Drum Bung Wrench, Standard Bronze Oil-Gate Valve for 2-inch Bung

POLYGEL SPRAYER

Drierite Cartridge

Drum Deheader

Meters, mixes and sprays select Polygel rubbers and plastics. Makes superior quality molds and shells much faster than hand application using self thickening Polygel rubbers and plastics.

METER MIX EQUIPMENT

Drum Cradle

DRYING CARTRIDGE PROTECTS PRODUCT INTEGRITY - Drums of Polyurethane products

(both Parts A & B) benefit from use of Drierite Dessicant Cartridges. The cartridge is screwed into the small bung with an adapter so that air entering the drum during dispensing is dry. Protects product integrity. Drierite Cartridges have a window to view color change to determine when cartridge is spent. Drierite Cartridge and Adapter sold separately. Poly 74-55 drum unit ready for use with valve, cradle and Drierite cartridge.

Meter mix and dispensing equipment automatically measures, mixes, pumps or sprays Polytek liquid rubbers and plastics. For recommendations on this type of equipment, call Polytek Customer Service at 800-858-5990.

PORTABLE SPRAY SYSTEMS

Certain Polytek polyurethane and silicone liquid mold rubbers and plastics ( e.g., Polygel rubbers & plastics, accelerated 1512X polyurethane plastic & TinSil Spray 25) can be inexpensively meter mixed and sprayed using sprayer assemblies and accessories from Plas-Pak Industries. Two gun assemblies are available - a 1:1 mix system for polyurethane rubbers and plastics and a 1:10 sprayer for TinSil Spray 25. Both sprayers are available from Polytek and come equipped with a pressure regulator kit and a Mixer/Spray Gun Assembly. You need to supply the air compressor. Empty cartridge assemblies (one tube for Part A and one for Part B are molded into one piece for convenience) and static mixers are sold separately. Cartridge assemblies may be reused when handled carefully or disposed if cleanup is impractical. Static mixers are disposable and should not be reused. With this handy spray system you can complete a mold in a one-application session. For recommendations on this type of equipment, call Polytek Customer Service at 800-858-5990.

Drum Hand Truck

Hand Truck

Accessories

Pallet Truck

For larger volume applications, Polytek products can be purchased in totes. Polytek also offers accessories for handling and dispensing products from totes. Call Polytek for details.

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TRIAL UNIT ORDER POLICY

GLOSSARY
Blanket Mold: A thin blanket-like rubber mold, usually - to -inch thick. A rigid shell (mother mold) is required to hold the floppy blanket mold in perfect shape. Chasing: The process of cleaning unwanted material (flashing) from a casting. Flashing: 1. Unwanted fin-like projections of casting materials that have flowed into mold vents and parting lines. 2. Thin aluminum sheet used to divide mold sections. Inhibition: Failure of a compound to cure against a surface within the recommended cure time. The surface in contact with the pattern remains gummy or uncured. Inhibition is most likely to occur in addition-cure (PlatSil) silicone systems. Keys: Tongue-and-groove, or button-like impressions to align mold or shell sections. Mother Mold (Mold Shell): The rigid shell over a flexible mold that holds the flexible mold in the desired configuration. Model: The original shape over which a mold is made. Parting Line: The line where sections of a mold or mold shell divide. Release Agent: A coating applied to prevent liquid rubbers and resins from sticking to surfaces. Resin: A liquid that can be cured to a solid plastic. RTV: Room temperature vulcanizing. Shims: thin strips of material used to form parting lines. Undercuts: A configuration such as an overhang between two mated surfaces, such as a mold and model, that tends to prevent them from separating when pulled apart. Flexible mold materials allow molds to be made with limited undercuts because the flexible mold material bends as the part is demolded. Accessories 65

See for yourself! Try Our Introductory Offer.

To encourage you to evaluate our products, Polytek will ship you the trial unit(s) freight paid (except for hazardous material fees, if any) in the contiguous 48 States at special low prices. Only one trial unit shipment of each product per customer. Subsequent orders are at list price. Directions and MSDSs are sent with trial units. All trial unit orders must be prepaid. Freight is free for accessories shipped with a trial unit, up to the value of the trial unit. Call for details.

TRY YOUR LOCAL DISTRIBUTOR FIRST

Polytek has stocking distributors worldwide; more every day. Call Polytek to learn the name and location of the distributor in your area.

NOTES & POLICIES

Prices are per unit, including both A & B. (Except one-part materials and certain epoxies.) Terms are 1% 10 days, net 30 days for accounts with approved credit. Orders prepaid with credit card, money order or wire transfer will usually be shipped the next day providing items are in stock. Orders prepaid with check are subject to delayed shipment until the check clears. No COD Shipments. Prices do not include state and local taxes. State tax exemption certificate required for PA customers. Prices are subject to change without notice. Prices are FOB Easton, PA. Freight will be prepaid on shipments valued over $4,000 for delivery in the contiguous 48 States. Minimum order $40; also applies to trial units. Any single pint size bottle of Silicone Part A is the full 1-lb kit price for that product. Any -gal size bottle of Silicone Part A is the full gallon-size kit price for that product. Minimum charge for any small container is $5. All video and book sales are final. No returns or refunds. Returns must be pre-approved and a 20% stocking charge is charged on all returns. Return Check charge is $25.

TRADEMARKS
Polytek, Polygel, Polypoxy, Poly-Optic, Poly-Sil, FormRub, Hydrogel, PlatSil, TinSil and Pol-Ease are registered trademarks of Polytek Development Corp., Easton, PA 18042 USA. Registration is pending for EasyFlo, PolyFoam, Poly LiteCast, EpoxyBond, Poly Purge and PolyBond. Cab-O-Sil, Tietex and Forton are marks of their respective manufacturers.
www.polytek.com

Liquid Rubbers & Plastics for Mold Making & Casting

Polyurethane RTV Mold Rubbers . . . . . .32-39
Poly 74, Poly 75 & Poly 77 Series Rubbers Our Most Popular Mold Rubbers! With hardnesses that range from a soft, stretchy Shore A~20 to a very firm Shore A~90, these rubbers find innumerable uses as tough, long-lasting mold rubbers or for making rubber parts, forms or stamps. Many of these systems have 1:1 mix ratios and all are easily mixed by hand or can be machine dispensed because of their low viscosities and other user-friendly characteristics. These polyurethane rubbers are designed for casting concrete, plaster, wax, and resins/foams with the use of appropriate release agents. Poly 74-20 has been designed for high-volume concrete casting where the highest level of elasticity and performance is required. Poly 74-30 is ideal for wax casting in foundry applications. Firmer versions of the 74, 75 and 77 Series rubbers are recommended for casting plaster and concrete as well and are chosen based on hardness and other specific physical properties needed depending upon the size, shape and nature of the master being duplicated or part being cast. Consult Polytek's technical support staff for assistance in choosing the right rubber for your application! Polygel Brushable/Sprayable Rubbers - Patented Polygel mold rubbers are 1:1 mix liquids that thicken upon mixing Parts A and B to a brushable or sprayable viscosity. Polygel 50 can be applied about -inch thick while Polygel 35 & 40 are thinner for best detail penetration. With Polygel Spray 35 & 50, you can make a large mold in an afternoon and cure it overnight. Poly GlassRub - GlassRub 50 is a clear, pale-blue, glass like rubber for casting flexible art objects or for cut molds. Poly-Fast 72-40 Series Rubbers - These fast-setting rubbers (8-hr demold) can have varied hardnesses by changing mix ratio or adding Part C. Can be thickened for brush-on molds with Cab-O-Sil or Part D. Poly 81 Series Rubbers - High-performance, RTV, elastomers for parts, tools and molds. Low moisture sensitivity. Hardnesses of D45 and A90.

Silicone RTV Mold Rubbers . . . . . . . . . .40-45

TinSil 70 Series Silicone Rubbers - Many products, from soft A10 to firm A60 hardness. Best for casting resins and 70-60 is acceptable for casting low melting metals. Consider TinSil 70 Series systems for best economy. PlatSil 71 & 73 Series Silicone Rubbers - Consider platinum-cured PlatSil 71 & 73 Series for highest performance. Several easy-to-use, 1:1 mix ratio systems with 4-hour demolds are available. PlatSil Gel-10 Silicone Rubber - Translucent, soft silicone for delicate casting projects and special effects. Use to make simulated skins and prosthetic appliances that can be applied directly to an actor or for aniimatronic effects.

Specialty Molding/Casting Materials . . .57-60

Latex Rubber Products - Poly Latex 60 is a one-part, thickened, natural latex for brush-on molds that are strong and durable. When thinned with Poly Latex N, Latex 60 can be sprayed using an inexpensive cup gun. Poly Latex False Face Compound is a one-part, high strength, casting rubber for novelty masks, flexible sculpture and animatronics. False Face can also be used for dipped molds. Poly Wax 15 and Poly Skin-Wax - Poly Skin-Wax has a very low melting point with good toughness after cooling for making molds of hands, feet and delicate objects with limited undercuts. Poly Wax 15 is mineral filled for casting in most rubber molds to make recarvable models. HydrogelN Mold Compound - Mix this powder with water to make a rubbery mold in minutes. Yields excellent mold impressions if plaster or wax is cast right after setting. Safe for body contact. Epoxy Resins and Curatives - Polypoxy 1010 is a general-use, low viscosity, epoxy resin. Mix with Poly Cure 1212 and bronze or other metal powders for production of cold-cast bonded bronze in rubber molds. Call for information about other epoxy systems.

Casting Plastics/Resins . . . . . . . . . . . . . .46-56

EasyFlo Series Plastics - Easy 1:1 by volume mix ratio, odorless, resins cure to a white or clear plastic in minutes. EasyFlo 60, 95, 120 & Clear are super low viscosity, fast casting plastics: great for rotocasting and bubble-free parts. Also used for making cold-cast bonded bronzes. Poly 15 Series Casting Resins - Filled Poly 15-3 and faster 15-3X are excellent for casting parts, molds and tools. Poly 15-6, 1511 and 1512X make strong, lightweight mold shells. Poly 1510, 1511, 1512 and 1512X are water thin, with a great thermoplastic feel for prototypes. Poly 15-8 is aluminum-filled for applications demanding heat-resistance. Poly-Optic 14 Series Crystal Clear Casting Resins - Poly-Optic 1410 and 1411 are non-yellowing, Shore D85 plastics. Poly-Optic1420 must be heat cured and is buffable. Poly-Optic 14-70 is a clear rubber with a Shore A70. Poly Lite Cast - Has a wood-like feel and can be carved, cut, sanded and drilled. Poly Plasti-Flex - A flexible plastic for decorative trims and castings. Polygel Plastic-75 & Polygel Shell - Easy, 1:1 mix ratio, use these resins for making mold shells fast. PolyFoams - Cast these easy (1A:1B) rigid & flexible foams in closed molds packed to 4-20 lb/ft3 densities to produce parts replicating wood, terra-cotta, stone, etc. Use in PlatSil or TinSil molds.

Accessories . . . . . . . . . . . . . . . . . . . . . . .61-64
Polytek offers many accessories so you can obtain all your mold-making supplies from a single source! Pol-Ease Release Agents - Aerosol Pol-Ease 2300 & 2500 and waterbased Pol-Ease 2601 allow for easy release of rubbers from models and resins from molds. Pol-Ease 2650 is best for high volume concrete and plaster applications. Poly Adhesives & Bonding Agents - PolyBond is a flexible, high performance, polyurethane adhesive for many applications. EpoxyBond & Quick Stick are epoxy systems for similar rigid bonding applications. PolyFiber, Bronze and Other Fillers Safety Equipment - Polytek sells gloves, coveralls, solvent cans and more. Work safe! Mixers, Scales, Books and Videos & Other Equipment Our latest training DVD demonstrates various mold making techniques and is only $5.95! Polytek can suggest rotocast machines and meter-mix pumps/sprayers to dispense liquid rubbers & plastics to meet your particular requirements. Please call to let us help!

See Our Low Cost Trial Unit Order Policy - p. 65