Casting foam like "Fypon"

[Chuck Keysor]

Hello Shopbot friends. I am interested in trying to use my Shopbot to make a master/original product. Then I'd like to make a "rubber" mold, and then cast the end products out of light weight yellow foam plastic. One example of this type of end product is Fypon. I would think this type of work is common with a number of Shopbotters.

I see that Smoothon seems to offer everything needed from mold making to casting materials, including training. But I have no experience with that company or their products. Maybe there is a company you like better.

1) Do any of you do this type of work, and have sources that you recommend for molding materials and casting materials?

2) Can any of you recommend good on-line training resources for getting an over-view of these products and then for learning the details of using them to provide good results?

3) Is there an industry trade magazine for these types of products, or an on-line forum?

Thank you, your personal recommendations and suggestions will help me focus my search! Chuck

[mezalick]

Chuck,
I do this as a regular part of our business.
We use Polytek for all the materials.
https://www.polytek.com/
There are several companies making similar products, but this is what we use..
Try it all and don't be afraid to make some mistakes.
Michael

[Keith Larrett]

I have used the SmoothOn Mold Max 60. I use it to make molds to cast pewter.

Smooth On have a wealth of videos both on their website https://www.smooth-on.com/tutorials/ and on their YouTube page https://www.youtube.com/user/SmoothOnInc

I purchased the mold materials from http://www.reynoldsam.com/orlando/ but this is just a Smooth On distributor that is relativly close to me. You can find a list of distributors at https://www.smooth-on.com/distributor-regions/usa/

I think the first step is to identify what you are going to be casting and then work backwards from there in terms of finding a suitable mold material and method.

I don't think you could go wrong with the Smooth On products. Be warned though it is a slippery slope! It's quite amazing watching the videos and seeing what they do with the various products.

[Chuck Keysor]

Thank you Michael and Keith for your thoughtful and detailed replies! I have plenty to do,,,,

I would be interested to see things that people have cast where they have made their master using their Shopbot. Such examples can be inspiring and motivating.

Thanks again, Chuck

[mclimie]

Funny - I just saw this video on casting larger rigid foam panels/props, and they deal with materials savings techniques, too.

https://www.youtube.com/watch?v=eca4wq2c0lA

Marc

[Chuck Keysor]

Thanks Marc! That was an excellent video with good, practical tips! Chuck