Materials

1. F-20 Plus silicone + catalyst

2. F-Plus Silicone Catalyst - Technical Data Sheet

Product Description
The F-Plus Catalyst is an additive specifically formulated for the vulcanization of RTV (Room Temperature Vulcanizing) silicones. It is used in combination with F-Plus silicone to create high-quality flexible molds, suitable for various applications in industry and the arts.
Key Features
Mixing Ratio	2% - 3% catalyst by weight of silicone
Form	Transparent or slightly opaque liquid
Curing Time	Depending on the amount of catalyst used, curing can range from 30 minutes to 24 hours
Ease of Use	Easy to dose with a syringe for accurate measurement
Instructions for Use
Mixing: Add between 2 and 3 grams of catalyst per 100 grams of F-Plus silicone. Mix thoroughly: Ensure the catalyst is completely blended with the silicone for proper vulcanization. Application: Use the mixture in the pouring process or brush-on method on the object to be replicated. Curing: Allow curing at room temperature for the specified time (depending on the amount of catalyst used).
Catalyst Properties
Adjustable curing speed	Using more catalyst will speed up curing, while using less will slow down the curing time.
Versatility	Suitable for all types of molds, including those used for casting pieces in resin, plaster, polyurethane, wax, jewelry, ceramics, and more.
Compatibility	Compatible with other F-Plus silicones and similar-quality RTV products.
Usage Precautions
Avoid direct contact: Do not allow the catalyst to come into direct contact with skin or eyes. Storage: Keep the catalyst in its original container, in a cool, dry place, away from heat sources. Safety: Wear gloves and safety goggles during handling to avoid irritation.
Benefits
Curing time control: Allows adjustment of the curing speed based on project needs. High-quality molds: Proper use of the catalyst ensures molds with excellent tear resistance, flexibility, and precision. Easy to measure: The catalyst formula is designed for easy measurement, ensuring a perfect mix every time.
Available Sizes
100 ml container	For small projects
500 ml container	For medium-sized projects
1 liter container	For larger projects or industrial use

Important Note:

It is recommended to use a scale to weigh the silicone and a syringe to measure the catalyst in order to ensure precise mixing.

Silikast-Pro Polyester Resin Technical Data Sheet

The resin will be used for casting applications.(This information was sourced from ChatGPT.)

Product Description
Silikast-Pro is a high-quality unsaturated polyester resin designed for general molding, laminating, and other applications that require good mechanical and thermal resistance. It is ideal for mold manufacturing, automotive parts, repairs, and various applications in industrial and artistic fields.
Key Features
Type	Unsaturated Polyester Resin
Color	Transparent or slightly yellowish
Composition	Polyester base + Styrene monomer
Working Time (Pot Life)	15–30 minutes, depending on ambient temperature and catalyst amount
Curing Time	30 minutes to 1 hour (full curing may take up to 24 hours depending on the thickness of the piece)
Density	1.1 – 1.2 g/cm³
Viscosity	2000 – 3000 cps (depending on temperature and formulation)
Curing Properties	Requires a catalyst (Methyl Ethyl Ketone Peroxide, MEKP) to initiate the curing process
Instructions for Use
Mixing: The resin should be mixed with the catalyst in a typical ratio of 100 parts of resin to 1-2 parts of catalyst (depending on the manufacturer's instructions). Application: Apply the resin through pouring or laminating onto the mold or object to be fabricated. It can be used with fiberglass or directly on the desired surface. Curing: Allow curing at room temperature (18–25°C) for the specified time. Recommendation: It is important to test the mixing ratios and working time to determine the exact catalyst proportions depending on ambient temperature.
Mechanical Properties
Tensile Strength	60 – 80 MPa
Flexural Strength	85 – 95 MPa
Impact Resistance	10 – 15 kJ/m²
Modulus of Elasticity	3.5 – 4.5 GPa
Thermal Properties
Heat Distortion Temperature	80 – 90°C
Coefficient of Thermal Expansion	50 – 60 x 10^-6 /°C
Applications
Mold Manufacturing: For producing resin, plaster, cement, and other material castings. Automotive Industry: Repairing parts or manufacturing components. Surface Repairs: For fiberglass, wood, metal, etc. Artistic Manufacturing: Sculptures, decorative pieces, etc. Fiberglass Laminating: For structures and coatings.
Usage Precautions
Avoid direct contact: Do not allow the resin to come into direct contact with skin or eyes. Wear gloves, goggles, and appropriate clothing. Ventilation: Use in well-ventilated areas due to fumes released during curing. Storage: Store the resin in its original container, tightly closed, in a cool, dry place, away from heat sources and direct light.
Available Sizes
1 kg container	Ideal for small projects
5 kg container	For medium-sized projects
20 kg container	For industrial use or large-scale projects

Important Note:

The characteristics of the resin may vary depending on the type of catalyst and mixing conditions. It is recommended to conduct tests before large-scale production.

Polyester Resin Catalyst Technical Data Sheet

Product Description
The Polyester Resin Catalyst is a compound that, when mixed with the resin, initiates the curing (vulcanization) process of the polyester resin. This catalyst is essential for ensuring that the resin hardens and acquires the desired mechanical and thermal properties.
Catalyst Usage Method
Mixing Ratio	Add between 1.5% and 2% catalyst to the total amount of resin, or 10 to 20 drops per 100 grams of Silikast-Pro resin.
Mixing	After adding the catalyst to the resin, mix thoroughly for at least 1 minute to ensure the mixture is homogeneous.
Instructions for Use
Measure the desired amount of resin. Add 10 to 20 drops of catalyst per 100 grams of resin (approximately 1.5% - 2% of the total amount). Mix the resin and catalyst thoroughly for 1 minute to ensure a homogeneous mixture. Once mixed, proceed with the application of the resin for molds, laminating, or other desired applications.
Usage Precautions
Avoid direct contact: Avoid contact with skin and eyes. Wear gloves and protective goggles when handling. Ventilation: Use in a well-ventilated area to avoid inhaling fumes. Storage: Store the catalyst in its original container, in a cool, dry place, away from heat sources and direct sunlight.
Available Sizes
50 ml bottles	Ideal for small projects
100 ml bottles	For medium-sized projects

Conduct and compare molding tests.

Visual Comparison of Molds

Feature	3D Printed Mold	Silicone Mold
Detail Precision	High	High
Mold Surface	Smooth	Variable
Fabrication Time	Long	Moderate
Reusability	Low	High
Cost	Moderate	Low
Ease of Demolding	High	High

Both molding methods have advantages and disadvantages depending on the type of project and the resources available. The 3D printed mold is ideal for quick prototypes and complex designs, while the silicone mold offers flexibility and durability for longer production runs. The choice between one or the other will depend on factors such as available time, budget, and the nature of the final product.

Comparison of Molds: 3D Printing vs CNC Milling

The following table provides a comparison between the molding methods using 3D printing and CNC milling, based on the process, production time, cost, precision, and recommended applications.

Aspect	3D Printing	CNC Milling
Manufacturing Process	Uses a 3D printer to create the mold from an STL file. Direct process without additional tools.	Uses a CNC machine to mill the mold from a material block. Requires programming and tool selection.
Production Time	The estimated time for printing is approximately 4 hours and 56 minutes.	Time varies depending on design complexity, but is generally longer due to the machining process.
Cost	Low initial costs, ideal for prototypes and small-scale productions.	Higher initial costs due to the need for specialized tools. More cost-effective for mass production.
Precision and Surface Finish	May show visible layer lines affecting the surface finish, but post-processing can smooth the mold.	Offers a smoother and more precise surface finish, especially with materials like aluminum.
Design Flexibility	Allows for complex geometries and customized designs without significant limitations.	Limited by tools and material geometry, which can restrict complex designs.
Recommended Applications	Ideal for rapid prototyping, low-volume productions, and custom designs.	Best suited for mass production, durable molds, and when high precision is required.

Conclusion:

The choice between 3D printing and CNC milling depends on the specific needs of the project. 3D printing is ideal for rapid prototyping and small-scale productions, while CNC milling is better for large-scale productions requiring high precision and durability.

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This week involved creating molds using two different techniques. First, a rigid mold was fabricated through 3D printing, providing a solid and detailed base. Simultaneously, another mold was made using CNC routing on a suitable material, which was carefully cleaned after cutting to ensure quality. Silicone platinum was then poured over this rigid mold to create a flexible and elastic mold, ideal for accurately reproducing parts and facilitating demolding without damaging the original object.

This process combined digital technologies and advanced materials to explore different molding and casting methods, emphasizing the importance of precision, flexibility, and safety in material handling.

Personal Protective Equipment (PPE)

To ensure safety during the handling of platinum silicone and other materials used in mold making, the following personal protective equipment was used:

• Disposable plastic or latex gloves:
  These gloves protect the skin from direct contact with the liquid silicone, which can cause irritation or allergic reactions. They also prevent cross-contamination of materials and keep hands clean during the process. It is recommended to change gloves regularly to maintain effectiveness and avoid potential harm.
• Respiratory protection mask with filters:
  During mixing and pouring of the silicone, vapors and particles that could irritate the respiratory tract may be released. Using a mask with specialized filters helps prevent inhalation of these contaminants, especially in closed or poorly ventilated environments, protecting the operator's respiratory health.
• Adequate ventilation of the work area:
  It is essential to work in a well-ventilated space or equipped with extraction systems to disperse any vapors or particles, complementing the protection provided by gloves and mask.

These measures help minimize risks and ensure a safe environment during the molding and casting process.

Datasheet Explanation for BBDINO Super Elastic Silicone Mold Making Rubber Platinum

The material used to create the flexible mold is a highly elastic and high-precision platinum silicone. According to its safety datasheet, this silicone has the following key characteristics:

• Material type: Platinum silicone, offering great elasticity and flexibility, ideal for accurately reproducing complex parts and facilitating demolding without damaging the mold or original piece.
• Curing time: The silicone cures in approximately 8 to 12 hours at room temperature (~25°C). This time can be accelerated by applying controlled heat up to 50°C, which helps optimize the production process.
• Toxicity and safety: In liquid form, the silicone may cause skin and eye irritation, so direct contact should be avoided and proper personal protective equipment used. Once cured, the silicone is non-toxic and safe to handle.
• Non-flammable: The material poses no fire risk under normal working conditions.
• Storage: Should be kept in a cool, dry place away from heat sources or direct sunlight to maintain its properties.
• First aid: In case of skin or eye contact, rinse immediately with plenty of water and seek medical advice if symptoms persist. If vapors are inhaled, move to fresh air.

These properties make this silicone suitable for manufacturing high-quality flexible molds that can be reused in multiple production cycles without losing detail or durability.

Procedure for Using BBDINO Super Elastic Silicone Mold Making Rubber Platinum

1. Preparation of the rigid base mold:
   Before pouring the silicone, the rigid mold (obtained by 3D printing or CNC routing) must be completely clean and free of dust, grease, or residues. This ensures good adhesion and avoids imperfections in the final mold.
2. Measuring and mixing the silicone:
   The silicone usually comes as two components (base and catalyst) that must be mixed in a 1:1 ratio by volume or weight, as specified by the manufacturer. Accurate measurement is crucial to ensure proper curing.
3. Homogeneous mixing:
   Mix slowly and thoroughly to avoid air bubbles that can affect the mold's surface quality. In some cases, a vacuum degassing system can be used to remove bubbles.
4. Pouring over the rigid mold:
   Pour the mixed silicone slowly onto the rigid mold, starting from one edge to allow the material to flow and cover the entire surface without trapping air.
5. Curing:
   Allow the silicone to cure at room temperature for the recommended time (8–12 hours) or accelerate the process by applying controlled heat (up to 50°C). Time and temperature must be respected to ensure optimal properties.
6. Demolding:
   Once fully cured, carefully remove the silicone from the rigid mold, obtaining a flexible and elastic mold that faithfully reproduces the original details.
7. Cleaning and storage:
   Clean the flexible mold if necessary and store it in a cool, dry place to preserve its properties and extend its useful life.

Safety Recommendations During Use

• Constant use of personal protective equipment (PPE):
  Always wear disposable gloves and a mask with filters during mixing and pouring to avoid skin contact and inhalation of vapors or particles. Use safety goggles in case of splashes.
• Adequate ventilation:
  Perform work in well-ventilated areas or with local exhaust systems to disperse vapors released during curing.
• Careful measurement and mixing:
  Avoid spills and splashes that may cause unnecessary exposure. Use clean, appropriate containers for mixing.
• Handling tools and molds:
  Clean and dry tools properly after use to avoid residue buildup that could cause cross-contamination or unexpected reactions.
• Safe storage:
  Keep silicone components sealed in their original containers and store them in a cool, dry place, out of reach of children and pets.
• Emergency procedures:
  Have clean water available for rinsing and a plan for quick medical attention in case of irritation or accidents.

Results

Photo

Video

Datasheet Explanation for PLA Used in 3D Printing

The rigid mold produced by 3D printing was made using PLA (Polylactic Acid), a common thermoplastic polymer used in additive manufacturing. According to typical PLA datasheets, this material has the following properties:

• Material type: Biodegradable thermoplastic derived from renewable resources such as corn starch or sugarcane. PLA is popular due to its ease of printing and good surface finish.
• Printing temperature: Recommended extrusion temperature is typically between 190°C and 220°C, depending on the specific filament brand and printer setup.
• Glass transition temperature: Around 60-65°C, which limits its use in high-temperature environments as it can soften or deform.
• Mechanical properties: PLA is rigid and has good tensile strength, making it suitable for functional parts and molds that require structural stability.
• Toxicity and safety: PLA is considered safe and non-toxic during printing, but it is recommended to use printers in ventilated areas to avoid inhaling ultrafine particles.
• Environmental impact: Being biodegradable, PLA is more environmentally friendly compared to many other plastics, though it requires industrial composting conditions for effective degradation.
• Storage: PLA should be kept dry and stored in sealed containers to prevent moisture absorption, which can affect print quality.

These characteristics make PLA an ideal material for producing rigid molds via 3D printing, offering dimensional accuracy and ease of post-processing.

Results

Photos

Michael's mold

Andres's mold

Comparison Between the 3D Printed PLA Mold and the Silicone Flexible Mold

Aspect	3D Printed PLA Mold	Silicone Flexible Mold (BBDINO Platinum)
Material Type	Rigid thermoplastic (Polylactic Acid)	Flexible platinum-cured silicone rubber
Flexibility	Rigid, limited to no flexibility	Highly elastic and flexible
Durability	Good structural stability but prone to cracking under stress	Excellent durability, withstands multiple demolding cycles without damage
Detail Reproduction	Good surface finish, dependent on printer resolution	Excellent fine detail reproduction, especially on complex geometries
Curing / Production Time	Printing time varies from hours to days depending on size and settings	Requires more time: design of negative mold, CNC routing, pouring silicone, and curing (~24 hours)
Heat Resistance	Glass transition around 60-65°C, softens under heat	Stable under higher temperatures, depending on silicone grade
Use Cases	Ideal for producing rigid molds or prototypes	Ideal for flexible molds, complex shapes, and delicate demolding
Safety and Environmental Impact	Biodegradable and generally safe to print; requires ventilation	Non-toxic once cured; requires PPE during handling liquid form
Cost	Relatively low cost per mold, depending on filament and printer	Material cost is higher; reusable mold reduces long-term cost

Final Results

3d Pritner mold

Flexi Mold

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1.-Materials

2.-Features of Wax as a Filler for Plaster Molds

In this process, wax was used as a pattern (model) inside a mold made of plaster, following the classic methodology of investment casting or lost wax, but first we will see its characteristics and then continue with the process.

A. Product Identification

Commercial name: Plaster of Paris / Ceramic plaster

Chemical name: Calcium sulfate hemihydrate (CaSO₄·½H₂O)

Recommended use: Casting molds, sculpture, crafts, casting molds, construction.

Technical Characteristics of Plaster

• Material type: Plaster (calcium sulfate hemihydrate), a porous and easy-to-mold material widely used for molds and sculptures.
• Color: White or slightly grayish.
• Setting time: Plaster sets between 5 and 30 minutes, depending on the mixture and environmental conditions.
• Compressive strength: Moderate, between 3 and 10 MPa, suitable for general-purpose molds.
• Porosity: High, allowing moisture absorption and facilitating casting with materials like wax.
• Hardness: Low to medium (approximately 3 on the Mohs scale).
• Density: Around 2.3 g/cm³.
• Thermal conductivity: Low, approximately 0.17 W/m·K, helping manage temperature when casting hot materials.
• Applications: Casting molds, sculptures, wax molds, and plasterwork.
• Advantages: Cost-effective, good detail reproduction, easy to prepare.
• Limitations: Fragile, moisture sensitive, low impact resistance.

B.-Product Identification

Commercial name: Paraffin wax

Chemical name: Saturated hydrocarbon mixture (mainly n-alkanes)

Recommended use: Lost wax casting, modeling, candle making, and prototyping

Technical Characteristics of Wax

• Material type: Paraffin wax, a mixture of saturated hydrocarbons derived from petroleum, commonly used in modeling and casting.
• Color: White, yellow, or colorless, depending on purity and additives.
• Melting point: Between 46°C and 68°C, depending on the formulation.
• Density: Approximately 0.9 g/cm³.
• Viscosity (liquid): Low to medium, allowing easy flow into detailed molds.
• Hardness: Soft and malleable at room temperature; becomes brittle at low temperatures.
• Thermal conductivity: Very low, about 0.2 W/m·K.
• Thermal expansion: Moderate; expansion must be considered when designing molds.
• Applications: Lost wax casting, artistic modeling, candle making, prototyping.
• Advantages: Easy to melt and handle, excellent for fine detail reproduction, reusable.
• Limitations: Flammable, susceptible to deformation in heat, brittle when cold.

Procedure of CNC Machining and Wax Casting

The process began with the creation of a digital design using ArtCAM software. Once the model was finalized, the corresponding toolpaths were generated and exported as G-code for CNC machining. A block of plaster was pre-prepared by mixing and pouring it into a container, allowing it to set and dry completely. This block served as the material for subtractive manufacturing. The CNC machine precisely carved the design into the plaster. After machining, the mold was cleaned to remove any dust or residue. Paraffin was then melted and carefully poured into the machined plaster mold. Once the wax had cooled and solidified, the final step was to demold the wax piece, which accurately captured the details of the original digital model. This workflow effectively combines digital design, CNC technology, and casting techniques to produce highly detailed wax models.

Preparation of Plaster mold for Machining

The video shows the preparation of plaster with water according to the indicated proportion, it dissolves so that it does not generate lumps.

3.-Features Mold manufacturing using 3D printing and silicone

Characteristics of PLA (Polylactic Acid) for 3D Printing

• Material type: Biodegradable thermoplastic derived from renewable resources like corn starch or sugarcane.
• Printing temperature: Typically between 180°C and 220°C.
• Glass transition temperature: Around 60°C to 65°C.
• Strength: Good tensile strength and rigidity, suitable for detailed prints and prototypes.
• Flexibility: Relatively brittle compared to other filaments like ABS or TPU.
• Environmental impact: Biodegradable under industrial composting conditions.
• Odor: Low odor during printing, making it suitable for indoor use.
• Ease of printing: Easy to print with minimal warping and good adhesion to the print bed.
• Applications: Prototyping, educational models, toys, and decorative objects.

Characteristics of Silicone

• Material type: Elastomeric polymer known for flexibility, durability, and heat resistance.
• Curing time: Typically 8 to 12 hours at room temperature; can be accelerated with heat.
• Elasticity: Excellent flexibility and tear resistance, ideal for molds requiring detailed reproduction.
• Chemical resistance: Resistant to water, chemicals, and temperature variations.
• Applications: Mold making, casting, medical devices, and sealants.
• Toxicity: Generally non-toxic and safe when fully cured.

Comparison: 3D Printing vs. CNC Milling for Mold Making

Aspect	3D Printing	CNC Milling
Manufacturing Method	Additive (builds layer by layer)	Subtractive (removes material from a solid block)
Design Complexity	High — easily handles complex and organic shapes	Limited — best for simpler geometries or requires complex toolpaths
Surface Finish	May need post-processing (sanding, coating)	Smoother finish achievable directly
Material Options	Primarily thermoplastics and resins	Wider range including metal, wood, wax, plastic
Production Speed	Faster for small and complex parts	Faster for simple geometries and larger volumes
Tool Access Limitations	None — can create enclosed/internal structures	Yes — limited by tool angles and reach
Durability of Mold	Depends on material (resin prints may be brittle)	Typically stronger, especially in hard materials
Cost	Lower for prototypes or one-off parts	Higher setup cost but efficient for repeated use