Urethane Resin Casting for Awesome Molds

Use either ComposiMold or ImPressive Putty for Urethane castings.

Many people use urethane resins because of their versatility and relatively simple use. Most urethane casting materials are 1:1 mixes with short casting times ranging from 1 to 30 minutes. Urethane plastics are used for making models, prototypes, crafts, and art pieces. 

Polyurethane resin casting in ComposiMold

Urethane resin in ImPRESSive Putty

Quick tip for success with urethane casting resins and ComposiMold:

With ImPRESSive Putty, faster cure urethane casting resins work really well. The mold making putty can handle the higher temperatures of the fast cure urethanes. 

For ComposiMold, choose a urethane with a longer cure time. These create less heat as they cure. You can also experiment with freezing the mold prior to pouring higher temperature urethane resins. Be sure to use talc powder/baby powder as your mold release before each casting made.

ComposiMold works very well with many urethane resins. However, there are two potential issues with some urethanes:

• Some fast cure urethanes create a lot of heat when they cure, which can melt the ComposiMold. You can work around this by chilling your mold first, adding fillers into the urethane before casting, or pouring the resin in intervals.
• Some urethanes are very sensitive to moisture. Use talcum powder as a mold release to reduce any moisture from the mold from reacting with the urethane.
• Use a mold release that is designed for polyurethane casting.

ComposiMold has two urethane resins available that we believe work very well with ComposiMold:

• Protocast Urethane Casting Resin: off white, easy mix, easy pouring, rigid urethane,
• Purecast Urethane Casting Resin: 100: A to 13: B Color Semi-transparent, Reddish/Brown Shore Hardness –50D-60D Gel Time about 10 minutes

Urethane resins require dry fillers. Any water will create bubbles and heat. If you using powdered fillers in the polyurethane, dry the material in the oven at low temperatures for 15 to 30 minutes prior to mixing. 

Pouring ComposiMold mold for resin casting

Making wheels from Urethane resin in ComposiMold mold

Visit Polyurethane Casting with ComposiMold for videos.

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To Mold and Cast a Rubber Ducky into a Plastic Duck using ProtoCast and ComposiCast Urethane Resin

This is a simple one part mold of a rubber duck. To stop the rubber duck from floating when the ComposiMold is poured over it, clay and sand was put inside the rubber duck. It also could have been glued down with hot glue to the bottom of the container.

The part was then coated with Bubble Buster to reduce bubbles from adhering to the part. We dip it into the Bubble Buster, but we could also have sprayed it on. Be sure to get it into any crevices.

The duck is placed inside a mold box. We used a PVC pipe, but any container that can handle a little heat will do. You can also use legos to build a box or aluminum foil that has been sprayed with a mold release also works well.

Melt the ComposiMold and pour over your part. To melt the ComposiMold, follow the direction on the label. Melt in short intervals until you are comfortable with how it melts in your microwave. You can also use a double boiler or a chocolate melter.

A toothpick or paperclip can be used to pull bubbles away from any areas where bubbles may stay such as in undercuts or sharp corners. In this case, we expect bubbles to adhere to the neck area and below the beak.

We don’t show it in this video, but the ComposiMold is cooled rapidly by placing it in the freezer. It took approximately 30 minutes to cool, but to ensure it was very cold before pouring in the urethane resin, we left the mold in the freezer for 2 hours.

You then remove the duck from the mold and spray the inside of the mold with a mold release that is designed for urethane resin.

The ProtoCast urethane resin is a bright white plastic with a demold time of 15 to 20 minutes.

While the mold is still cold, pour in a PrototCast Urethane resin. The urethane is mixed 1:1 by volume.

If necessary, place ComposiMold back into the freezer to keep the mold cold while the urethane is curing. This helps reduce any melting of the ComposiMold from the exothermic reaction from the Urethane. Longer cure time resins have less of this heat.

At this time, the plastic duck is made. You can remelt the mold to make a new mold, or you can make another casting with the ComposiMold mold.

Here we also show the plastic duck made with ComposiCast urethane resin. It works the same way. Be sure to keep the mold cool if necessary throughout the process.

• The keys to success for a urethane casting is to use Bubble Buster when making your mold
• Keep the ComposiMold cold throughout the process
• Use a mold release designed for urethane resin and make sure it is completely dry.
• And if possible, use longer cure time resin systems.

Thank you!

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Cool Casting Examples using ComposiMold

We put together a compilation of some of the newer castings made with ComposiMold and PowerMold. Enjoy and thanks for the inspiration!

Now Available ComposiMold Urethane Starter Kit! Learn to Make Plastic Parts

100% Reusable Mold Making Material and Easy Flow Polyurethane Resin

Learn to Mold and make Plastic Castings Worry Free

Everything you need to start making your own plastic parts. And if you make mistakes-don’t worry. Remelt the ComposiMold reusable Mold making material and try again.

Each ComposiMold Urethane Starter Kit contains everything you need to begin molding and casting:
• ComposiMold 1 pound container
• 2 pounds of Plastic (1 pound Part 1 and 1 pound Part 2)
• Mold release for Plastic
• 5 Mixing sticks
• 2 filters for filtering ComposiMold
• Funnel for holding the filters
• Cups for Mixing Plastic • Instruction book

The Instruction Book starts with simple instructions on how to use the ComposiMold material followed by mold making instructions for a simple ComposiMold mold and plastic casting. This initial mold making and casting is followed by more complicated molds that are typically two part molds. Then we describe how to mix and use the plastic. We do our best to answer many of the typical questions in the Frequently Asked Question Chapter. We then go into ideas for other methods to make molds and castings. As you experiment you will begin to see how the process works and learn what works for you. The book ends with ideas for further mold making. (10 chapters, B&W 8.5x11, 38 pages)

ComposiMold is a reusable mold making material that works by melting and pouring. Many casts can be performed using the same mold. ComposiMold is good for the mold maker and craft artist because it can be reused to make different molds without worrying about wasting mold making material (such as urethanes, silicones, or Alginate). ComposiMold is an excellent material for those wanting to learn and become involved in sculpting, modeling, and mold making without having to worry about mistakes or wasting material. ComposiMold is flexible, rubbery, molding material that can be melted poured and reused. This material is a thermoplastic mold making material that is great for small mold parts using many different casting materials including plaster, cement, epoxy, polyurethane, and others. ComposiMold can be used for molds, mold making and as a resin.

ComposiCast-3770 is a two component 100% solids urethane casting system. It is easy to process, with a low exotherm (maximum 170°F) that demolds in 15 – 20 minutes. The ComposiCast-3770’s low exotherm works exceptionally well with the ComposiMold Reusable Mold Making Material. The ComposiCast-3770 uses a 1:1 mixing ratio (by weight and volume) and solidifies to a beautiful off-white color. The texture is similar to a lightweight porcelain feel.
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ComposiMold Figurines Molded with ComposiCast Urethane Casting Material

Tiny rabbits. Nice and simple mold and casting. This was a simple little rabbit placed into a small cup. The melted ComposiMold was poured over top and allowed to solidify. Because it was a small mold, it took about an hour to cool. The mold was sprayed with a mold release and the ComposiCast urethane resin was poured into the cavity. Ten minutes later the first rabbit was removed.

 

This little guy was a character from my youth. He is about an inch tall. The process for making him was basically the same as the rabbit. The mold was with ComposiMold and the urethane was ComposiCast.

Thanks and enjoy!

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ComposiMold Fishy Wall Casting

Here's a cool fish urethane casting made with ComposiMold Mold Making Material and ComposiCast urethane casting resin.  The original part, made by Helene Farrar was made with terracotta clay and sealed with a shellac spray.  

Since this is a one part mold, the ComposiMold-LT was poured over the fish and allowed to solidify by cooling. A mixture of 1-teaspoon white glue and 1 cup of water was used as the mold release for the casting.  For the casting a silicone mold release was used.

For more information:
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or to order visit:
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Newest video. How to Mold and Cast Plastic Soldiers with ComposiMold

The images of the soldiers at the end where made with ComposiCast urethane resin. The blue figures were also ComposiCast, but a blue die was added. The red soldiers were made with red candle wax.

Army Soldiers cast in ComposiMold molds