Thanks Ghost. The silicone is from Smooth-On. There are less expensive alternatives, but my friend Shawn is better educated as to what works best and what the differences are. I just "borrow" whatever he has for my projects in exchange for helping him with his projects. The process is actually pretty easy, but there is a considerable investment in the correct tools and materials.
As to the mold making, after the prototype piece is completed, it is coated in a print coat of silicone. The print coat silicone is thick like maple syrup and will coat the prototype, but will end up pretty thin. The next three layers of silicone were the same material but mixed with a thixotropic additive (I'm sure I spelled that wrong, but I can barely pronounce it half the time). These layers go on pretty thick, like cake frosting and add thickness to the mold. I've been told that the final mold should be about 1/2 inch thick.
The fiberglass mother mold gives form to the rubbery silicone mold so that it keeps it's shape. I used three layers of fiberglass cloth over each side, with some extra thickness where the two sides bolt together for added strength.
The good news is that I have made the first casting in the mold and it fits my head with plenty of room. The bad news is that my friend Shawn took the pictures of me wearing it with his camera and I have none to post.... Shawn... a little help please... you said you would post these...
As to the mold making, after the prototype piece is completed, it is coated in a print coat of silicone. The print coat silicone is thick like maple syrup and will coat the prototype, but will end up pretty thin. The next three layers of silicone were the same material but mixed with a thixotropic additive (I'm sure I spelled that wrong, but I can barely pronounce it half the time). These layers go on pretty thick, like cake frosting and add thickness to the mold. I've been told that the final mold should be about 1/2 inch thick.
The fiberglass mother mold gives form to the rubbery silicone mold so that it keeps it's shape. I used three layers of fiberglass cloth over each side, with some extra thickness where the two sides bolt together for added strength.
The good news is that I have made the first casting in the mold and it fits my head with plenty of room. The bad news is that my friend Shawn took the pictures of me wearing it with his camera and I have none to post.... Shawn... a little help please... you said you would post these...
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