How to: Silicone Mold & casting Flexible Foam 

@BJBEnterprises -thanks-that makes sense.i have used your products before,and have ALWAYS had great results ! -keep up the great work

Very nice professional job that came out perfect. Thanks for showing us.

This looks so fun and interesting!

Many technical schools for design and also art schools will have classes on mold making. Many people learn these skills on the job. Otherwise, You tube is a great resource for how-to videos. To learn which materials can be compatible with one another, it is best to call our technical staff to discuss a project.

Thank you for your comment. We will enhance our videos to do as you mention in the near future. As far as Australia not being creative, we find that there are many talented BJB customers in your part of the world and some of the biggest movie productions in the world are coming from your neighbor New Zealand.

Thank you! There are many amazing things you can make with our products. -BJB

Yes, some people will use a mold like this for fiberglass parts but keep in mind that epoxies and polyesters will be harder on the silicone materials so you may experience shorter mold life. An additional mold release sprayed in may help extend the life of the mold.

impressed !!

@iruss71 Yes, you can laminate fiberglass and resin systems (epoxy, polyester, etc) into silicone molds. In general, Silicone mold material has very high temperature resistance and can withstand post cure temperatures required in some laminating systems. You may want to use an appropriate mold release (spray waxes, Par-films, etc) with the silicone to ensure mold longevity. Some users do not use a mold release but mold life may suffer. Mandrels are also popular with silicone material.

The TC-265 Flex-Foam is rated at 2.5-3.5 lb/cu. ft. It's a soft "cushion-style" foam. We have a newer formulation called TC-266 that is very similar in properties but features an adjustable ratio. TC-266 at a ratio of 50/100 pbw produces a soft, open cell, quick recovery foam with a density of 3 pounds. At 30/100 pbw, the result will be a softer, open cell, slower recovery foam with a density of 5 pounds.

Awesome thanks

@Appaloosakisses We have a couple classifications of flexible foam that we formulate. Cushion style foams are typically soft and lack a rubbery skin. The lower their density, the softer they feel. We also have "Self Skinning" foams which do build more of a skin with enough back-pressure in the mold. For the same density as a cushion style foam, they are firmer and less compressible. Stay tuned for a new video on foams from BJB.

@filmmaker91361 Leaving the Master part in the mold, you would put some appropriate mold release onto the first mold flange (Vaseline works well) and then repeat the process in the video. When done you will have a two piece mold. Silicone will bond to itself but does not bond to most other hard, clean surfaces.

@CGkawaiicrafter The short answer is No; the foam would still release from the silicone mold but it is still advised to use a light application of mold release so the skin formed on the foam is not stressed as the part is de-molded. Often times we see that if soft foam is cast into a silicone mold without release, more force is required to de-mold the part and the skin might tear or pull away from the part. We recommend our E302 "Rocket Release" for use with foams.

@game33able It is TC-5024 with SC-5001 Thickening agent. This system is a two-part silicone molding material that is normally a flowing, castable product. Adding the SC-5001 makes it brushable and will hang in thicker sections. You can contact us to order product from the website address in the video.

The foam is a two-part liquid resin (urethane) that will expand after being mixed. The product number is TC-265 A/B and it cures to a 2.5-3.5 lb density. It cures to become a soft, flexible foam and bonds to the skin previously brushed into the mold. There are different foams available that vary in hardness and weight. These foams can also be pigmented to make colored foam parts right out of the mold.

great video! one question: what kind of mold release is bjb challenge 90? I mean what are the coumpounds? Thanks for show and share!

Cool video. No release agent?

@Vyruzz2 Yes, we do ship all over the world. You would need to contact us through our website for pricing information and instructions on how to order material. We process many International orders so it is only a question of shipping costs for your material requirements. Thank you for your interest. -BJB

nice video I'm using the spray can foam on my Austin Healey to do a wide body Body kit . Thanks for the Video

nice I like it

Yes, Sculpey can be used as a master pattern. You would want to be sure that the silicone you use is a "Tin-Based" system and not a "Platinum" based catalyst. Sculpey may contain some elements of sulfur that will cause curing issues with a Platinum silicone. The Blue silicone you see here is our TC-5024 Tin-Based with TC-5001 thickening agent to make it brushable.

I want a flexible mold to cast a rigid and paintable positive. I think I might put a layer of gauze in the meddle to increase strength. Any suggestions? The subject would be a 3-D landscape.

What product would you recommend for making a mold to replicate intricate plaster crown molding. This is additionally complicated as part of the pattern is tin ceiling crown molding. so i cannot remove a piece off the wall unfortunately and have to do it off the wall. thanks

Is there a book you recommend for making molds and casting?

Is there a book of casting and making molds you recommend?

@tuuexx The person applying the spray shell had the settings set too high with regard to material flow. If the gun and spray head is set correctly, there should not be dripping of material. To answer the questions about other backing material, you can apply fiberglass/polyester (or epoxy) or plaster if you prefer. The spray material is best utilized on larger surface areas for quick mold shells because you can demold within hours as oppose to a day or more.

where can i get a list of thing to get to make at home? i like to make a ridged Styrofoam body out of a mold and a second hollow shell to wrap around the firm Styrofoam ridged frame

Yes, a wax model would work fine. The silicone will not have any problem curing against and releasing from wax.

The Blue silicone is TC-5024 A/B with SC-5001 Thickening Agent. The rigid urethane shell that is sprayed onto the back of the silicone is SP-200 A/B. See our website to download Data Sheets.

Excellent video, it's one of the things i've been looking for, don't think the wrong thing, but i've been wanting to make flexible body parts. I would recommend talking us through it all instead of the music, other than that, thankyou so much for posting the info. Now i just have to find the products in Australia, australias not very creative sometimes :)

cool

@moraisdesantana yes , silicone is good for fibreglass casts, use a wax release first

How do you determine the range of flexibility of urethane foam. What is the determination between softer and firmer?

caracas esse produto e miuito bom

Great vid !!! 8:18 Is that a bubble on it's left upper lip ?

po show de bola esse produto

Yes, this mold and part is a demonstration of materials but you can complete the whole head as one piece.

If anyone has an object on a wall they want to make a mould from and they can't remove the object it can be done. You can make a mould on the wall.

How would you make a two-piece mold of the entire head?

Can you put the back of the head together with the front and pour them together to make the whole head?

I have a HUGE question . Okay so I am just starting out . Like LITERALLY just started out. I'm still just a kid , but i dream of one day becoming like Glenn hetrick . I know I wont be doing molds and stuff for awhile . But I was wondering if there are any tips or trips to make it easier ://

i just love the idea of this but i am not patient enough nor able to do this, i was just wondering if you could do me one as a robot and the reverse side too for the back of the head in a chrome look effect which joins together by some kind of fastening so I can start a robot act as a dj again but without make up also wondered if there could be a chest compartment to assist with the head which i could add led blue lights to it for extra effects, please let me know I really need help to acquire these props im in the uk thanks again brilliant video too ;)

What company do you get your supplies from is it affordable

informative

If I make a silicone mold, I can make a fiberglass helmet with this mold?

@oslocrimecity2 You can order directly from us over the phone or via email. If you contact us we can send pricing of the materials you are interested and the Data is on our website. We ship international orders every day and always welcome interest from outside the USA. Best regards!

can you please tell me the density of the foam you used ?

BJB is a supplier of molding and casting materials. Please check out the website and you can acquire pricing through customer service. -Regards

if hardened yes

interesante

There are 2 different types of castable silicone: Tin and Platinum based. It is not recommended that you use a Tin based against the skin. You'll find that most medical grade or skin safe silicones are Platinum based.

reminded me of hon solo for some reason...

WHAT IS THIS BLUE MOLD STUFF WERE DO i get it?

Where does one learn these things?

It is a very cost effective method on larger tools but could also work on smaller tools if the detail and geometry allow. It is more labor intensive compared to casting/pouring the silicone but if you are not in a hurry then you can certainly build small tools this way. -BJB

2:00 I thought it was a crossbow :3

This seems like it wastes much less materials than simply mixing silicone and dumping it into a mold basin. Can this be done with most molds that you would usually just do a silicone pour for? Silicone is pretty expensive after all so I'd like to save as much as possible...

can a Sculpey piece be the master?

Does anyone know what this robot is from? I feel like i've seen it before.

The finished article had a defect on the right side of the mouth (lip)

part 5 i didin't understand anything , I'm a beginner , .....

so thats how you make a crash test dummy

that spray-on shell process sure looks to waste alot of matrial-sure brush-on is,nt a cheaper way-or polyester resin...or plaster?