How to cast hollow parts in a mold using wax, clay, epoxy and cement

Introduction

This tutorial provides a comprehensive guide on how to cast hollow parts in a mold using various materials such as wax, clay, epoxy, and cement. By following these steps, you can create accurate duplicates of your hollow parts using ComposiMold, a reusable mold-making material. This process is particularly useful for artists, hobbyists, or anyone interested in creating custom objects.

Step 1: Prepare the Mold with Mold Release

• Apply a mold release agent to the interior surfaces of your ComposiMold.
• Ensure an even coating to facilitate the easy removal of the cast part after curing.
• Allow the mold release to dry for a few moments before proceeding.

Step 2: Create the Hollow Core

• Use toothpicks to secure the mold core in the center of the mold.
• Position toothpicks around the core to create voids, which will be essential for the casting process.
• Confirm that the core is stable and centered to ensure uniform casting.

Step 3: Cast with Clear Casting Plastic

• Mix the Clear Casting Plastic in a 1:1 ratio (part A to part B) by weight or volume.
• Pour the mixture into the mold, ensuring to fill it adequately.
• Allow the casting to cure for 24 hours.
• After curing, carefully remove the part from the mold.

Step 4: Cast with Wax

• Chill the mold in a freezer to enhance the casting quality.
• Melt the wax and wait for its temperature to drop below 170°F (77°C).
• Pour the wax into the mold, swirling it around to cover all surfaces evenly.
• Allow the wax to cool completely before removing it from the mold.

Step 5: Cast with Clay

• Apply mold release to the mold surfaces as before.
• Push the clay deeply into the mold, ensuring all details are captured.
• Carefully remove the clay piece from the mold.
• Smooth out any imperfections on the surface.
• Allow the piece to solidify, then fire it in a kiln for durability.

Step 6: Cast with ComposiStone

• Again, prepare the mold with mold release.
• Mix ComposiStone at a ratio of 1 part water to 2 parts ComposiStone by volume.
• Pour the mixture into the mold and use your hands to brush it around, ensuring all sides are evenly coated.
• Wait for 1 hour for the ComposiStone to solidify.
• Remove the part from the mold and let it sit for 1 day before applying any paint.

Step 7: Re-melt and Re-use ComposiMold

• To create a new mold, re-melt the ComposiMold material.
• Use the melted material to form a new mold as required for your next project.

Conclusion

By following these steps, you can effectively cast hollow parts using a variety of materials. Whether you use epoxy, wax, clay, or ComposiStone, each method offers unique advantages depending on your project needs. Remember to always use mold release for easier part removal, and take your time during the curing processes for the best results. Happy casting!