MOLD MAKING & CASTING

Manual & Catalog

Discover the
Flexibility of
Liquid Mold
Rubbers and
Casting
Plastics

10th Edition
Advancing the State-of-the-Art in Art & Industry
TM
WELCOME!
Welcome to the 10th Edition of Polytek® Development Corp.’s
MOLD MAKING & CASTING MANUAL & CATALOG. We wrote this
manual to help you use the many products and materials Polytek
offers to their maximum benefit.
Mold making and casting are not easy. In fact, making molds and
castings is a full-time career for many skilled craftsmen.
An important part of a master mold maker's expertise is develop-
ing a “feel” for the way each different molding and casting mate-
rial behaves. Developing this “feel” for each material and learn-
ing to anticipate and avoid common problems takes a great deal
of practice with a variety of materials. Consequently, it is difficult
for anyone to try a new technique or use a new material the first
time and achieve perfect results. Thus, the old adage, "Practice
makes perfect."
Polytek has formulated a range of materials to help you achieve
your molding and casting objectives, and we are constantly work-
ing to invent new products to make your job easier.
As good as any material may be, however, the skill of the user is
equally important in achieving the objective. When you use a
material for the first time, we ask that you start small and simple
to get a “feel” for the material before going on to larger projects.
Our goal is to continue to produce depend-
able, quality materials and present their
basic methods of use. The rest is up to you.
We depend on your success and want to
help whenever possible.
Thank you for your patronage.
Sincerely,
Bob LeCompte
Chairman
POLYTEK’S LOCATION
Our state-of-the-art facility is located at 55 Hilton Street, Easton,
PA -- just off I-78, Exit 75. You can see us from the highway!
Stop in! We use our 5,000-ft2 mezzanine for product demonstra-
tions, trials, and seminars. Take time to enjoy nearby historic
Delaware River inns and attractions. We’re only 90 minutes to
New York City and Philadelphia.
CUSTOMER SERVICE
When you call Polytek, you can speak to a member of our customer
service team (Joe, Stan, Wendy, Dave, Laurie, Jill, Mary, Larry and
Bill). They all have hands-on experience and the knowledge and abil-
ity to satisfy your needs quickly. Whether you’re new to mold mak-
ing and need help getting started or an expert mold maker looking for
a fresh perspective, we welcome your questions. We know that our
continued success is based on the quality of our products and service
and the word of mouth of satisfied customers.
MOLD RUBBERS & CASTING PLASTICS
Polytek offers the most complete line of mold making and cast-
ing materials available anywhere. For mold making, Polytek pro-
duces polyurethane and silicone liquid rubbers in many hard-
nesses as well as latex, alginate and wax. For casting, Polytek
manufactures rigid and flexible polyurethane plastics and foams
and castable epoxies. Polytek is a one-stop source for mold mak-
ing needs: we offer a full line of accessories including release
agents, training DVDs, scales and more. If we don’t have what you
need, call us -- we can develop custom formulas within weeks.
SEMINAR & WORKSHOP
Polytek offers a popular, two-day seminar and workshop titled
“Mold Making and Casting Methods and Materials.” The first
day begins with a comprehensive presentation and demonstration
of mold making techniques and materials. Later in the day the
workshop portion gets started. Attendees are encouraged to bring
a small, simple model. Polytek’s expert technicians review each
model and discuss mold making options with the group. Then
each attendee gets hands-on experience using Polytek’s products
to make a mold and casting of their model. Enrollment is limited
to 20, meaning that each attendee gets plenty of one-on-one guid-
ance from Polytek’s staff. The seminars are conducted in
Polytek’s well-equipped, 5,000-ft2 mold making and casting shop
in Easton, PA. The cost is $400 for the seminar and workshop
(includes materials) or $200 for the first day only (with no hands-
on use of materials). Call for seminar dates. Enroll early!
Seminars fill fast!
(610)559-8620 • (800)858-5990
 Mold Making Methods . . . . . . . . . . . . . . . . .2
CREATIVITY WITH CHEMISTRY

Mold Making
1
Mold Making & Casting Materials

Methods
Types of Flexible Molds & Castings
The remarkable, life-size Carrara
Mold Making & Casting Procedures
marble sculpture by E. Zocchi of a
young, enthusiastic Michelangelo Applications
carving a gargoyle depicts four of
our favorite things ... art ...
creativity ... enthusiasm ... and
Polyurethane RTV Mold Rubbers . . . . . . .32

gargoyles!
Use Polytek products creatively
and enthusiastically for a variety
of projects -- from creating fine art
to producing functional pieces for
home and industry. Mold making
and casting are truly CREATIVITY
WITH C HEMISTRY . The use of
Polyurethane
Mold Rubber
2
Poly 74, Poly 75 & Poly 77 Series Rubbers
Polygel® Brushable/Sprayable Rubbers
Poly 81-Series Rubbers
Poly-Fast 72-40 & Poly GlassRub Rubbers
Silicone RTV Mold Rubbers . . . . . . . . . . . .40

Mold Rubber
Polytek materials is limited only
TinSil® 70 Series Silicone Rubbers

Silicone
by the imagination -- may yours PlatSil® 71 Series Silicone Rubbers
be limitless. PlatSil® 73 Series Silicone Rubbers
PlatSil® Gel 10 Silicone Rubber

CONTACT INFORMATION Casting Plastics/Resins . . . . . . . . . . . . . . .46

Casting Plastics
4
EasyFlo & Poly 15 Series Plastics
Poly-Optic® 14 Series Clear Casting Resins
BY PHONE
PolyFoam, LiteCast, Plasti-Flex & Polygels®
(800) 858-5990 Epoxy Resins & Curatives
(610) 559-8620
Monday to Friday
Specialty Molding/Casting Materials . . . . .57
8:30 a.m. - 5:00 p.m.

5
Latex Rubber Products

Speciality
Materials
Poly Wax 15
BY MAIL Poly Skin-Wax
Polytek Hydrogel® N Mold Compound
55 Hilton St.
Easton, PA 18042 Accessories . . . . . . . . . . . . . . . . . . . . . . . . .61

6
Pol-Ease® Releases

Accessories
PolyFiber, Bronze and Other Fillers
ONLINE Safety Equipment
sales@polytek.com Mixers, Scales, Books, DVDs & More
www.polytek.com
Secure credit card transactions
DISCLAIMER: The information in this catalog and otherwise
provided by Polytek® is considered accurate. However, no warranty
is expressed or implied regarding the accuracy of the data, the
results to be obtained by the use thereof, or that any such use will
BY FAX not infringe any patent. Before using, the user shall determine the
(610) 559-8626 suitability of the product for the intended use and user assumes all
risk and liability whatsoever in connection therewith.
24 hours a day
© 2007 by Polytek Development Corp. All rights reserved. This
manual may not be copied, in whole or in part, without written
consent of Polytek Development Corp.

1
www.polytek.com
 1 Mold Making Methods
Mold Making
Methods

GETTING STARTED To have a successful mold making experience,

PLEASE ...
When making a flexible mold of an object in order to cast
reproductions, you are faced with many choices of mold making Š Study. Read as much "how-to" literature as
and casting materials and methods -- it can be bewildering at possible. Watch instructional DVDs and
first glance. In order to succeed, you must consider many factors
videos (see p. 63).
before you start a project. Here are a few things to think about:
Š What is the model made of? Š Start Small. Make a small, simple mold and
Š Does the shape of the model present mold making or casting before attempting an important
demolding challenges?
piece. Get a feel for the materials without
Š What will the casting be made of?
costly mistakes. Experiment with small Trial
Š How many castings do you envision making?
Units (see p. 65).
Š How much money do you plan to spend?
Š How much time do you have to complete the project? Š Ask Questions. It’s difficult to tell you how
Think ahead. You need to plan your project from start to finish to make molds and castings over the phone,
before you begin. Read the “Methods” sections entirely so that but we’ll try! Please call Polytek Customer
you understand all of the factors that need to be considered
during the planning stage of your project.
Service with questions.

Each mold making and casting compound is unique and may

MOLD MAKING & CASTING MATERIALS
Polytek Development Corp. produces nearly all types of flexible
mold materials commonly used today as well as many casting
materials. Before beginning a mold making project, you must
understand the advantages and disadvantages of various mold
making and casting materials. At the same time, you must
consider the type of mold you envision, because that too will
play a factor in selecting appropriate mold making and casting
materials. For information about types of flexible molds, refer to
pp. 7-9.
Flexible mold materials range from simple, one-part latex (the
natural product of the rubber tree), Hydrogel® N (alginate, a
powder to which water is added), and Skin-Wax (which is
melted for use), to the higher performance two-part polyurethane
and silicone mold rubbers. Polytek’s two-part systems consist of
two liquids that after mixing together react to form rubber. These
systems cure at room temperature and, therefore, are are referred
to as room temperature vulcanizing (RTV).
require special handling that differs from similar products.
Spend time learning the special requirements of every new
product and making a small test mix before using the product on
a larger scale to avoid loss of valuable time and materials.
Mold making and casting materials must be selected con-
currently. This is because some casting resins work well only in
certain mold materials (and vice versa). If you have a specific
casting material in mind, then you select a mold material that
works well with that casting material. Most often you can find
mold and casting materials that work well together and satisfy
all of of your project requirements. The illustration below helps
to demonstrate this point.
Casting Mold Material
Wax All (except Skin-Wax)
Concrete Polyurethane
Plaster All (usually polyurethane)

Epoxy Polyurethane or silicone

Selecting proper mold making Polyurethane Silicone or polyurethane
and casting materials for the job Polyester Silicone or polyurethane

at hand is the 1st step to Acrylic Silicone or polyurethane

success! Metal (low-melting) Silicone or polyurethane

2
(610)559-8620 • (800)858-5990
 Mold Making Methods 1

Mold Making
Methods
SELECTING A MOLD MAKING MATERIAL
To select the best mold making material for your project, consider
One-part mold materials usually
several factors: model composition, shape and size; mold type; present more disadvantages than
cost; and timing. First, familiarize yourself with the common
types of flexible mold making materials and the advantages and two-part materials.
disadvantages of each. After you have learned about the various
mold materials, take into account the characteristics of your model Polytek’s two-part materials are
and the mold making challenges it presents.
The tables below highlight advantages, disadvantages, uses and
tough, long-lasting, easy-to-use
methods of application for various one- and two-part mold mold rubbers.
materials.

One-Part Mold Compounds

Type Advantages Disadvantages Uses Methods

Alginate • Safe for body contact • Very limited life; dries out • Body molds • Pour
Hydrogel® N • Gets model wet • Single-use molds • Layup

Wax • Safe for body contact • Low strength • Body molds • Brush-on
Poly Skin-Wax • Low cost • Limited use • Single-use molds • Dip
• Fast set • Must melt prior to use
• Reusable

Latex • High strength • Not dimensionally stable • Concrete • Brush-on

Poly Latex 60 • Takes days or weeks to • Plaster statuary • Spray
Poly Latex False Face make mold • Limited resins • Dip
• Oils can soften and
destroy molds
• Blanket molds only with
shell required

Two-Part Mold Rubbers

Type Advantages Disadvantages Uses Methods

Polyurethanes • Moderate to low cost • Requires careful • All materials • Pour

Poly 74, 75, & 77 Series • High strength release agent except molten • Brush-on
Poly 81 Series • Many versatile varieties • May be moisture metals • Spray
Poly 72-40 Series sensitive
Polygel®

Tin Silicones • No release agent • Higher cost • All materials • Pour

TinSil® 70 Series needed • Shrinks up to 1% on (especially resins • Brush-on
• High strength curing and low- • Spray
• Excellent chemical • Limited cured storage temperature
resistance life melting metals)

Platinum Silicones • No release agent • Higher cost • All material • Pour

PlatSil® 71 Series needed • Cure inhibited by some • Brush-on
PlatSil® 73 Series • No shrink on cure surfaces • Spray
• Good cured storage life
PlatSil® Gel-10
• High strength
• Excellent chemical
resistance

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 1 Mold Making Methods
Mold Making
Methods

Model Composition
A model’s composition or surface coating may restrict you to
certain mold making materials. Certain mold materials do not
cure properly over some model materials (i.e., platinum-cured
silicones do not cure on sulfur-containing clay models).
Sometimes, if the model’s composition presents a problem, it
can be overcome by carefully sealing the model (see p. 11).
Thoroughly review product technical bulletins to be sure that
there are no compatibility issues between your model and the
mold material you’ve selected. If your model is delicate or
valuable, it is best to try the selected mold material on a small
hidden area before you jump into mold making. Fragile models
can be damaged in the mold making process. The resulting
mold, however, can be used to make a reproduction out of a
more durable material. [Note: If the model is a human body,
there are obvious safety issues. Consider Hydrogel Mold
Compound or Poly Skin Wax (see pp. 59-60).]
Model Shape and Size
The size, shape, and even location of your model may limit you
to certain mold making materials and types of molds (i.e., a
model with deep undercuts does not lend itself to a simple box
mold). If you are restricted to a certain type of mold, then your
choices of mold materials may be limited.
Cost
Both the volume of material needed and the price per unit
volume must be considered in calculating project cost. The
quantity of mold making material needed is dictated largely by
the type of mold you choose to make -- a large model may
mandate a brush-on mold since any other type of mold would
require too much material. The quantity of material needed can
be calculated by estimating the volume of mold making material
needed (in cubic inches) and dividing by the specific volume
(cubic inches per pound) of the material (see box to the right).
To determine project costs more accurately, one also needs to
consider the time it takes to make the mold (see below).
$ Cost per cubic inch is your real cost --
price per pound can be misleading.
When using mold making or casting materials you are usually
filling a given space. The lower the cost per cubic inch of
material, the lower the cost of filling the space. “Specific
Volume,” expressed in cubic inches per pound (in3/lb), is the
key to calculating the real cost of a mold making and casting
material.
Some rubbers and plastics that have a low price per pound
contain dense fillers such as powdered marble or silica. These
fillers typically reduce the price per pound, but raise the price
per cubic inch. Simple calculations reveal the real cost of your
material in terms of cents per cubic inch.
Poly 74 Series Rubbers (see p. 34) are low density and
contain no heavy fillers. They yield 27.5 in3/lb. Poly-Fast 72-
40, a dense rubber, contains fillers and yields only 20 in3/lb --
nearly 1/3 less rubber volume per pound!
For example:
Š An 80-lb trial unit of Poly 74-30 costs $336 or $4.20/lb
($336/80 lb). Dividing $4.20/lb by 27.5 in3/lb yields a
cost of $0.15 per in3.
Š A 49.5-lb trial unit of Poly-Fast 72-40 costs $194 or
$3.92/lb ($194/49.5 lb). Dividing $3.92/lb by 20 in3/lb
yields a cost of $0.20 per in3.
Poly 74-30 = $0.15 per in3
Poly-Fast 72-40 = $0.20 per in3
At first glance it appears that Poly 74-30 is the more
expensive product; however, to fill a given space, using Poly
74-30 actually costs nearly 25% less than higher density
Poly-Fast 72-40 rubber. The photo below shows the dramatic
density difference between these rubbers.

Time Considerations
Timing plays an important role in the selection of a mold
making material. With some materials a mold can be completed
in an afternoon (i.e., accelerated silicone and polyurethane mold
rubbers), while with others, it can take weeks (i.e., latex rubber).
To learn more about demold times, read the technical bulletins
for individual products. Remember, the fastest material or
method may not be the least expensive.
Consider how long you intend to use and keep the mold. Some
materials are only suitable for one casting (i.e., Hydrogel), while
others will hold up for hundreds of castings (silicones and most
polyurethanes). Also, consider “library life:” how long you
expect the mold to remain useful after sitting on a shelf. Most
properly cured rubber molds are useable for many years, but
some degrade within 2 to 4 years (i.e., Poly 72-40 and TinSil
rubbers). For molds with long library life, use polyurethane
rubbers (except Poly 72-40) or PlatSil silicone rubbers.

4
(610)559-8620 • (800)858-5990
 Mold Making Methods 1

Mold Making
Methods
SELECTING A CASTING MATERIAL Mold Material Casting Material
To select the best casting material for your project, you must
consider several factors: mold composition and construction, Skin-Wax Low-exotherm materials --
required characteristics of the casting (i.e., weight, durability), polyurethane and silicone
cost, and timing. rubbers and select resins
First, it is a good idea to familiarize yourself with the common
casting materials and understand the general advantages and Hydrogel Materials that are not
moisture sensitive -- wax,
disadvantages of each. The most common and least expensive
plaster, silicones and
casting materials are gypsum plasters and cements, both of
select resins
which are available in many formulas for various end uses.
Waxes are castable, of course, but uses are limited by low
Latex Concrete, plaster and
hardness and high shrinkage. Low melting metals can be cast in select resins
heat resistant silicone molds. Epoxy and polyurethane systems
are versatile and durable casting materials. Polyester resin is Polyurethane Most casting materials are
quite low in cost, especially if low cost fillers like sand, acceptable, except metals
limestone or wood flour are added.
The table below presents common casting materials suitable for
use in molds made from Polytek flexible mold products. Silicone All casting materials are
acceptable
Mold Composition
A mold’s composition may restrict you to certain casting Molds made from Polytek products are non-porous and casting
materials. In a few cases, casting materials may rapidly degrade materials used in the molds should "cure" or set chemically. In
or even destroy the mold (i.e., exothermic epoxy resins will melt most cases, air drying materials are not suitable since the rubber
a wax mold). Carefully review product technical bulletins to be prevents them from drying except from the back. Water clay,
sure that there are no compatibility issues between your mold paper-mache, and latex are often not suitable casting materials.
and the casting material. The illustration above provides a general guideline regarding
suitability of casting materials depending on mold composition.

Casting Material Advantages Disadvantages End Uses

Wax • Easy demold • Fragile • Foundries
• High shrinkage • Candles
• Resculpting
Vinyl • One-part liquid • Requires high heat to use • Prototypes
• Parts
Gypsum Plaster • Fast • Indoors only • Most indoor objects
• Yields good quality • Brittle • Moulding
Concrete/ • Acceptable for outdoor use • Heavy • Statuary (indoor &
Specialty Concrete • Rough surface outdoor)
• Slow set • Architectural
ornaments
Design Cast and Forton® MG • Acceptable for outdoor use • Higher cost

Acrylic Resin • Clear • Expensive • Many diverse uses

• Difficult to use (painting may be
• Strong odor needed for outdoor
use)
Polyester Resin • Inexpensive • Flammable
• Strong odor
Epoxy Resin • Moderate price • Health hazards
• Limited mass
Polyurethane Resin/Foam • Moderate price • Moisture sensitive
• Easy to use
• Very versatile

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 1 Mold Making Methods
Mold Making
Weight of the Casting
Methods
Casting materials have different densities that affect the weight
and feel of the final casting. For example, plaster and concrete
are heavy, while resins are lighter. The weight of a casting can
often be controlled by adding fillers to the casting material.
Also, you can create a lighter, hollow casting, by using a "plug"
to prevent casting material from filling the entire mold, or by
laying up into or rotating a mold so casting material cures in a
thin shell on the mold surface. These techniques are discussed
on p. 10.
Exterior Durability of the Casting
Materials such as cement are fine for both indoor and outdoor
environments, whereas most other casting materials need to be
painted or sealed for outdoor use. Exterior castings are subject to
elements such as UV light from the sun, rain, and freezing and
thawing. Concrete and polyester resin castings are fine for
interior and exterior uses. Polyurethanes, however, must be
painted or sealed prior to being placed outdoors in order to avoid
yellowing and chalking of the bare plastic, which occurs over
time. Fillers, pigments and Poly UV Additive can be added to
improve exterior performance (see p. 61 for information on Poly
UV Additive).
Cost
Both the quantity of material needed and the price per cubic inch
must be considered in calculating project cost. The
quantity/weight of casting material needed is dictated by the
volume of material needed (in cubic inches) divided by the
specific volume (cubic inches per pound) of the casting material.
Here is a general idea about the relative costs of casting
materials.
High Cost Unfilled polyurethanes and epoxies
COST
Medium Cost Filled resins, speciality concretes
(i.e., Forton® MG)
Low Cost Concrete, plaster, wax, filled
polyester
Obviously, to determine true project cost one needs to consider
the time it takes to make the casting (see below).
Time Considerations
Timing plays an important role in the selection of casting
material. With some materials, a finished casting can be made in
minutes (i.e., EasyFlo 60 Plastic); while with others, it can take
days (i.e., concrete). The fastest material or method often is not
the least expensive.
Slow Concrete
TIME
Medium Plaster, wax, thin resins
Fast Polyurethane and polyester resins
6
“Exotherm” of Casting Material
Exotherm is the heat of reaction produced as a resin or rubber
cures. Polyurethane rubbers generally have very little
measurable exotherm. Poly 74-55 in a large mass may rise
just a few degrees above the temperature of the Parts A and B
before mixing. Epoxies, on the other hand, are much more
exothermic and, if poured in too large a mass for the heat to
dissipate, may get so hot that they boil and burst into flames.
Therefore, casting epoxies in large masses is dangerous and
must be avoided.
Consider exothermic heat when selecting casting resins. If the
casting is so thin that exothermic heat is easily dissipated into
the mold, the resin will be slow to cure, but there will be no
thermal shrinkage caused by gelling while hot then cooling.
Slow curing in these cases can be overcome by using warm
molds or using a faster curing system. Massive castings tend
to build heat in the center of thicker sections and sometimes
thinner sections of the same casting remain cooler. If the
temperature difference is too great, distorted parts or shrink
marks may be evident. Often, warm molds can help overcome
this problem as can addition of fillers or use of slower curing
systems. High curing temperatures shorten rubber mold life,
so proper selection of casting systems results in best economy
and longest mold life.
To reduce costs and cast larger masses,
ADD FILLERS to polyurethanes & epoxies.
Many fillers are suitable to add to liquid plastics to reduce
costs and help dissipate exotherm, which can cause shrinkage
and limit the size of the mass that can be cast at once. Heavy
fillers absorb more exothermic heat, but result in a heavy
casting. Lightweight fillers can make the casting lighter than
wood so it will float and carve easily. Some fillers such as
wood powder and nut shell flours may contain moisture and
cause foaming of the plastic or other problems. Dry fillers that
stir easily into the mixed resin are best. The cost per cubic
inch of resin displaced is the real cost of these fillers. For
example, some typical costs per cubic inch follow:
Filler $/lb Density (g/cc) $/in3
Dry Sand $0.05 2.75 0.005
Bronze Powder 5.00 8.85 1.590
Ground Limestone 0.15 2.70 0.015
Extendospheres CG 0.50 0.70 0.013
Q-Cel 2116 or 3M C/15 6.00 0.10 0.022
Adding an equal volume of low cost filler to a Poly Plastic
can cut the cost of the casting nearly in half! For example, one
cubic inch of resin at $0.14 plus an equal volume of filler at
$0.015 yields approximately two cubic inches costing $0.155
or about $0.07 per cubic inch for the mix.
(610)559-8620 • (800)858-5990
 Mold Making Methods 1

Mold Making
Methods
TYPES OF FLEXIBLE MOLDS
There are two basic types of flexible rubber molds: block molds
and blanket molds. Within these two basic types, there are
numerous variations differing in both construction and
complexity.

BLOCK MOLDS
Block molds are typically made by placing the model into a
containment area (i.e., mold box) and pouring liquid rubber over
the model. After curing, the rubber is removed from the model
and the result is a single-piece, poured block mold. This is the
simplest type of mold. Single-piece, poured block molds are best
for models with a relatively flat base or back and no sharp
undercuts that prevent the rubber from demolding from the Various molds and castings of ornate architectural elements
model. This type of mold would be used for reproduction of a and decor.
wall plaque.
Poured mold materials generally pick up detail with fewer
For a model with undercuts (i.e., the chin of a cherub’s face) a
entrapped air bubbles than materials that are applied by brush or
softer rubber can be used or the mold may need to be cut to
spray, except where bubbles on the surface of the rising liquid
allow for removal of the model and castings: this is referred to
are trapped under a ledge such as under the chin of a head
as a split block mold. In some cases, the block mold may need to
model. Tilting the mold box while pouring is a useful technique
be cut into or poured in several pieces to allow for removal of
for preventing air entrapment. If this does not help, a brush-on
the model and then carefully reassembled prior to casting: this is
mold, or pouring one section at a time may be advised.
referred to as a multi-piece block mold.
For diagrams depicting the procedures to make a single-piece
Sometimes, multi-piece block molds are made in sections, by
poured block mold, a split single-piece poured block mold, and
pouring on one surface at a time, allowing to cure, then pouring
a multi-piece poured block mold, see pp. 17-18.
on the adjoining surface against the previous pour. This
technique is necessary when the model has details on all sides A note on the terminology: Since a block mold is often made in
(i.e., does not have a flat base or back). box shape, it is sometimes called a box mold. However, this type
Poured molds are sometimes free standing if the rubber is thick of mold can be made in any appropriate containment area (i.e., a
enough to hold its shape, but often a box or rigid shell is used cylinder such as a piece of PVC pipe). Also, block molds are
with the mold to maintain its shape. Generally, the box or shell sometimes referred to as poured molds since this is the method
(“mother mold”) must be separate from the rubber mold in order used to make them.
to allow the mold to flex for removal of the model or casting.

Mold Complexity

Multi-Piece Poured Blanket Mold Contributing

Factors:
Poured Blanket Mold
Size
Complexity

Sprayed Blanket Mold Location

Shape
Brushed Blanket Mold
Time
Multi-Piece Block Mold Materials
Single-Piece Block Mold

Two-piece block mold

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 1 Mold Making Methods
Mold Making
Methods
BLANKET MOLDS
As the name implies, blanket molds resemble a thin blanket
carefully placed around the model. Blanket molds are made by
either brushing or spraying the flexible mold material onto the
model or pouring the mold material into a pre-constructed shell
around the model. With a few mold materials (i.e, latex, wax), it
is possible to make a blanket mold by dipping the model into the
liquid material. Blanket molds are generally ¼- to ½-inch thick.
To hold a blanket mold in its proper shape after the cured rubber
is removed from the model and during the casting process, a
rigid or firm mold shell (“mother mold”) is required.
Blanket molds are often mandated by the size and/or location of
the model. Since blanket molds consume far less rubber than a
conventional block mold, they are preferred for large or
irregularly shaped models. Typically mold rubber is sprayed or
brushed on large models. Often, blanket molds are the only
choice for large, immovable models (i.e., large gargoyle high on
a building facade).
With some models, blanket molds can be made in one piece and
lifted or peeled off the model and subsequent castings like a
sock; this is sometimes called a “glove mold.” A bas relief or a
figure with a pyramid shape (the bottom wider than the top) lend
themselves to one-piece molds. Molds that are to be turned back
on themselves and peeled off must be kept thin, usually less than
1/8-inch thick, to minimize stress and possible tearing of the
rubber. As the mold is peeled off, it may need to be lubricated
with silicone release or soapy water on the outside surface to
allow it to slide easily against itself.
For many types of models, the blanket mold must have a split
down one side to allow for easy removal of the model and to
reduce the chance of tearing the mold. The rubber at the end of
the seam may be reinforced with fabric at the top where a tear
may be likely to develop in the mold.
For complex models, blanket molds can be made in two or more
pieces. Shims or flanges are used to create seams or “parting
lines” where required on blanket molds and their shells. A split
blanket mold can be made by affixing a thin shim of aluminum
flashing, cardboard or stiff plastic film to the model projecting
several inches, applying release, and brushing/spraying the
rubber up against the shim. The shim should have keys or
indentations to allow the rubber flanges of each mold section to
THIXOTROPY:
The key to successful brush-on molds.
Thix.ot.ro.py \thik-`so-tr -pe\ n [fr. Gk thixis
e
act of touching]: the property of various gels
becoming more fluid when disturbed (as by
mixing) -- thixotropic adj
(Webster’s Ninth New Collegiate Dictionary)
8
One-piece, Polygel ® brushed blanket mold.
lock together to maintain position with respect to one another
and to the shell.
With the development of self-thickening and “thixotropic” (see
definition below) mold materials, making brush-on and sprayed
blanket molds has become routine. Not only do brush-on and
spray molds use less rubber, but they are generally faster to
make than poured blanket molds and offer the moldmaker visual
control of rubber placement.
In the past, blanket molds were often made by dipping the model
into or brushing on latex. Since each layer of latex must dry
overnight before the next layer can be applied, building up an
adequate thickness of latex for a useable mold can take weeks.
Trying to brush-on a pourable liquid without thickening usually
produces less than satisfactory results since the the liquid flows
off vertical surfaces. In order to make molds faster, moldmakers
add fillers to pourable mold rubbers in order to thicken the
uncured mix to a consistency that can be applied by brush. For
example, Poly 74-30 Liquid Mold Rubber can be mixed with
fumed silica (i.e, Cab-O-Sil®) to make brush-on blanket molds
(see photograph on p. 21). Many customers use this method
because it allows them to thicken the rubber to the exact
consistency that is desired and is the most economical method of
making brush-on molds. For more information regarding
thickening of liquid mold rubbers, refer to the product
descriptions (see pp. 34-45) or call Polytek Customer Service.
In 1992, Polytek received a patent for the Polygel® technology,
which enables the mixed Parts A and B liquids to immediately
react to form a gel with a consistency perfect for brush-on
application. Polygel 35, 40 and 50 Liquid Mold Rubbers are
ideal for brushing on a properly prepared model right after Parts
A and B are mixed. In addition, certain Polygel products have
been specially formulated for spray application (Polygel Spray
35, Polygel Spray 50 and Quick Spray 50). See pp. 36-37 for
information on Polygel products.
Whether using liquid rubber thickened with Cab-O-Sil or the
advanced Polygel products, a most important characteristic of
the mixed mold material for brush-on or spray application is
“thixotropy” (see box). To make a brush-on or spray-on blanket
mold, the rubber must be thick enough to not sag after
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 Mold Making Methods 1

Mold Making
Methods
have projecting keys or
Both brush-on and spray blanket rubber “snaps,” on its flange
and back so that the mold
locks into the shell to
molds are most easily made with prevent flopping out of
position. [Tip: Buttons of
®
Polygel Liquid Mold Rubbers. rubber, cast in advance in
plastic pill holders, can be
bonded onto the last coat of
application on the model, but also must be more fluid when it is the mold rubber so that the
mixed or moved around the model surface with a brush. Polygel shell is formed around them
products are thixotropic: they are thick enough to resist sagging holding the mold in position
when applied to a vertical surface, but are fluid when mixed and in the shell.]
moved around the model surface. Basically, the more energy you In the case of a poured
put into a thixotropic material, the lower the viscosity -- the blanket mold, the mother
faster you stir it the more fluid it seems. A good liquid rubber for mold is typically made
brush-on molds must become thixotropic shortly after Parts A before the rubber mold is
and B are mixed together -- that’s Polygel. made. After the mother mold Polygel ® rubber mold and resin
For diagrams depicting the procedures to make a single-piece is cured, it is positioned over shell made of Poly 15-6 Liquid
blanket mold, a split single-piece blanket mold, and a multi- the model and the liquid Plastic thickened with Poly Fiber.
piece blanket mold, see pp. 18-23. mold rubber is poured into
the void between the mother mold and model to make the
MOLD SHELLS (AKA “MOTHER MOLDS”) blanket mold. For more on this technique, see pp. 22-23.
A mold shell, also known as a “mother mold,” is not a A mother mold can last indefinitely and can help prolong the life
production mold but rather a shell that is required to hold the of a mold since a rubber mold stored in its shell can maintain
flexible rubber mold in its proper shape. The shell and mold are exact dimensions. The mold in its shell will last many years if it
used on the production line. Mother molds are sometimes used is stored in a cool, dry area out of sunlight. Still, when the
with block molds and are nearly always used with flexible rubber fails (as all flexible molds eventually do) the shell is
blanket molds. Mother molds can be made of plaster, plaster and simply repositioned over the model and a new mold is poured,
hemp, polyester resin and fiberglass, urethane foam, or one of ready for use the next day.
Polytek’s firm liquid rubbers or rigid liquid plastics. Poly 15
Series Liquid Plastics (15-6, 1511 and 1512X) and Polygel These three photos
Plastic-75 make tough, durable, lightweight mold shells in a illustrate the construction of
matter of minutes! For more information on 15-Series Liquid a poured blanket mold.
Plastics see p. 49; for Polygel Plastic-75, see p. 55. First, the model, a gargoyle
The mother mold is usually made over and is removable from face, is covered with clay.
the rubber production mold. Care must be taken so that a rigid Next, a rigid, plastic mold
shell does not lock onto undercuts in the block or blanket mold. shell (i.e., Poly 1512X, see
All such undercuts must be eliminated or the shell must be made p. 49) is constructed over
in multiple pieces to work around them. In certain situations, a the clay blanket. After the
firm but flexible mother mold can offer a good solution to plastic cures, it is removed
undercuts. A flexible mother mold, such as one made of Poly and the clay is removed
74-30 Mold Rubber, can be pulled off simple undercuts. You from the model. Then the
may use a little more rubber, but you can save lots of labor. plastic shell is repositioned
Mother molds are often two or more pieces even when the mold over the model and liquid
is one piece. The shell for a split mold would part along the line rubber (i.e., PlatSil® 71-11,
of the split in the mold. Parting lines for shells can be see p. 43) is poured through
established using plasticene strips applied to the cured rubber, an opening in the shell and
building up the shell against one side of the strip, removing the covers the model. Once the
strip, applying release and building the other half of the shell. rubber cures, the model is
When complete, the sections of the shell press the flanges of the removed and the mold is
rubber together like a gasket, keeping the parting line tight and ready to use. Cast away!
inconspicuous. If a brush-on mold is large, the rubber should

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 1 Mold Making Methods
Mold Making
Methods

TYPES OF CASTINGS
There are numerous types of castings and casting methods.
Castings vary by the type of material that they are made of (see
p. 2), and by the method employed to make them. The table
below summarizes the most common casting methods along
with the advantages and disadvantages inherent in each
technique and the products for which one might use each
method.
The photo to the right shows numerous castings made from
various Polytek casting plastics.

Casting Method Advantages Disadvantages End Uses

Solid Pour
Fast Heavy Small objects
Material is poured into the mold
resulting in a solid casting. Possible high cost Industrial tools

Gel Coat and Layup

Lightweight Time consuming Rigid molds
A thin surface coat is applied and
subsequent layers of reinforcing Less material used Mold shells
material like fiberglass mat and High quality surface Large objects
resin are built up to a thin, strong Bonded bronze
laminate.

Slush Cast
Material is manually rotated in the Lightweight Time consuming Art objects
mold creating a thin layer resulting Less material used Bonded bronze
in a lightweight hollow casting.

Rotational Cast
Fast Need a machine Larger statuary
A closed mold is rotated by Easy Hollow parts
machine as a small amount of
material coats the surface and sets, Lightweight
resulting in a hollow, lightweight Six-sided parts
casting.
Injection
Quality parts Requires setup time Manufactured parts
Liquid is forced into the mold
under pressure. Often need a machine

Vacuum and Pressure

Bubbles are eliminated, resulting Quality parts Requires setup time Prototypes
in perfect, high detail parts. Used Need vacuum pump/pressure pot Figurines
in conjunction with solid pour.

Direct Layup/Spray - No Mold

Material is spread over a screen Lightweight Time consuming Amusement/theme parks
armature. Surface detail is sculpted into Less material used Sculpted rocks
the wet material or plastic hardcoat
sprayed over carved foam substrate.

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MOLD MAKING PROCEDURES
This section guides you from model preparation through
finishing your casting. The directions provided here are general
in order to be helpful regardless of what mold making and
casting materials you choose and what type of mold or casting
you’re making. The following sections are presented in the order
that your project should proceed. Diagrams that depict
procedures for making a few different types of molds are
presented after the complete text description (see pp. 17-23).
SAFETY FIRST!
Before you even open your containers of mold making or
casting materials, understand the hazards of the materials that
you’ll be working with.
• Read material safety data sheets (MSDSs) and
product labels - MSDSs are sent with every Polytek
product and contain very important safety information.
Also, Polytek product labels have hazard warnings and
precautionary statements. Read the MSDS and labels
carefully so that you can use Polytek products safely. If you
do not receive MSDSs with your shipment, call Polytek
Customer Service and they will promptly get them to you.
• Understand health hazards - Some uncured Polytek
products can cause skin, eye and respiratory irritation if
improperly handled. Also, a few uncured products can
cause dermal and respiratory sensitization (i.e., allergic
reactions) in sensitive individuals. Avoid skin and eye
contact and breathing vapors from uncured materials. Do
NOT use Polytek products where food or prolonged body
contact may occur.
• Use personal protective equipment (PPE) and
engineering controls - Follow recommendations on
product MSDSs for use of PPE such as gloves, dust masks,
safety glasses or goggles, aprons, and, in limited cases, air-
purifying respirators with organic vapor cartridges. Use
products in areas with adequate ventilation such as a large
open room with air circulation.
READ DIRECTIONS
All too often, projects are spoiled because, in enthusiasm for
completing a project, important directions are not followed.
Before starting your project, read product technical bulletins and
label directions thoroughly. Call Polytek Customer Service if
you have any questions.
MODEL PREPARATION
Porous models, such as wood, plaster, stone, pottery or
masonry, must be sealed, then coated with a release
agent such as Pol-Ease® 2300 Release Agent or PolyCoat.
Sealing prevents rubber or resin from penetrating pores in the
model surface. Several coats of paste wax, allowed to dry and
polished or melted paraffin, petroleum jelly, lacquer, shellac,
www.polytek.com
Mold Making Methods 1
Mold Making
Methods
If you don’t follow directions ...
there is a lot that can go wrong ...
• Improper Mix Ratio - Slow, non-curing or
soft material can result if two-part materials are
not weighed or measured accurately. Always use
an accurate scale (see accessories, p. 63). Do
calculations carefully and double check the mix
ratio listed on labels and product literature.
• Release Agent or Sealer - Incorrectly
applied or missing, or use of the wrong sealer or
release can result is sticking or damage to the
mold/casting. If you’re not sure that you’ve
properly sealed/released a model, make a test
cure. Too much release agent can cause pinhole
surface defects or bubbles in the mold and/or
casting.
• Low Temperatures or Demolding Too
Soon - Deformed parts can result. Fluctuating
temperatures during curing can cause bubbles and
dimensional changes.
• Leaking Mold, Boxes or Shells - Your pour
can spill, wasting material and time. Use
mechanical fasteners and hold downs and be sure
that seams are tight and sealed.
• Material Hardens Before It’s In Place -
Avoid delays once material is mixed. Watch a clock!
• Unmixed Material - Streaks of uncured or
soft areas and/or gas bubbles can develop several
weeks after curing if Parts A and B are not
thoroughly mixed. Poorly mixed material is often
from the sides and bottom of the mixing container.
• Incorrect Material Selected - Choosing
the wrong material can result in sticking or
damage such as staining or softening a model,
mold or casting.
• Material Not Stirred Before Use - Some
components (Part A or B) must be stirred before
use. If the component is not carefully stirred
before mixing with its counterpart, soft cures or
bubbles can result.
• Contaminated Material - Moisture or
other foreign contaminants can spoil the cure of
materials. Freshly opened containers and clean
tools are important.
11
 1 Mold Making Methods
Mold Making
Methods
Important Terms
Cure time is often longer than demold time, sometimes even
though a product feels cured and can be demolded, curing may
continue for up to a week.
Demold time is the soonest a cured product can be removed
from the mold if it has been at recommended temperature.
Demolding castings as soon as possible helps to extend mold
life. Thin castings may require more time in the mold before
demolding.
Density is the weight of material that fills a given space. Water
has a density of 1.0 g/cc and a pound of water takes up 27.5
cubic inches. Thus a pound of material with a density of 2 g/cc
will only fill half the space or 13.75 cubic inches. When buying
mold rubber or casting resin you must consider the price per
volume, as the price per pound can be misleading. (See box on
“Cost per cubic inch,” p. 4.)
Elongation, reported in percent, is the length the material
stretches before breaking.
Hardness is measured with a Durometer. It pushes a needle-
like probe into the rubber as it is pressed against it. The
farther the needle penetrates into the sample the lower the
reading. The Shore A scale is used for rubbers and the Shore D
scale is used for plastics. Both scales go from 0 to 100. A
rubber with a Shore A hardness of 0 is like warm chewing gum.
Shore A10 to 20 is about as soft as any mold rubbers can be.
Shore A50 rubber is like a car tire. Above A80, rubbers feel
more like a plastic and may measure on the low end of the
Shore D scale. Shore D90 is about as hard as plastics get.
Pour time, working time, pot life or gel time give you an idea
how much time you’ll have to work with a material from the time
mixing begins until it gels. Most materials should be in place
well before the end of this time to allow good flow into detail
and for air bubbles to rise and break.
Rheology describes how a liquid flows. A liquid is Newtonian if it
flows and levels, even if very slowly. Pourable mold rubbers
should be Newtonian. Brush-on mold rubbers may be
thixotropic, that is they flow when brushed/troweled, but when
undisturbed they stay where they are placed (see box on p. 8).
Shrinkage is a reduction in size, which occurs with some
plastics during cure or some rubbers after prolonged use.
Casting materials draw oily materials out of the rubber causing
it to shrink. Products that develop heat during cure shrink as
they cool. The degree of shrinkage increases with the
temperature increase during cure. Some plastics get warmer in
the center than against the cool mold surface and tend to
cause the still liquid resin against the mold to sink. (See box on
“Exotherm,” p. 6.) Polytek products that stay cool during cure
do not shrink while curing.
Tear strength is reported as the force needed to tear a split
one-inch long in a piece of material. Higher elongation rubbers
generally have a higher perceived tear strength.
Tensile strength is the force required to break a piece of
material when pulled. It is reported in pounds required to break
a one-inch square specimen of material.
Viscosity, reported in centipoise (cP), describes if a liquid is
thick or thin. Water is low viscosity (1 cP), while pancake syrup
is higher (1000 cP), and honey is even higher (10,000 cP).
Temperature affects viscosity -- the lower the temperature,
the higher the viscosity. For best flow into detail, Polytek
materials should be at least room temperature.
12
paint, PVA (polyvinyl alcohol solution), and potters’ soap on
plaster all work well for certain surfaces and mold rubber or
resin combinations. Some rubbers (i.e., Poly-Fast 72-40) contain
materials that dissolve or soften lacquer and paints. For them,
wax or shellac are often used as sealers. Polyurethanes bond
tenaciously to shellac, however, so if shellac is used as the
sealer, release agent must be very carefully applied over it.
Bare plaster is best sealed with potters’ soap (or Murphy’s Oil
Soap) lathered into the damp surface of the plaster with a soft
brush, rinsed and repeated several times, then polished with a
soft brush or cloth. Only use soap on plaster, it is not suitable for
sealing with other materials. If the plaster is dry, it should be wet
for several seconds under running water prior to soaping.
Moist water clay, another special case, can be sealed and
released with Pol-Ease 2350 Release Agent or by spraying on a
10% solution of petroleum jelly in mineral spirits, made by
warming and melting the petroleum jelly and stirring in mineral
spirits. [Note: Use extreme caution since mineral spirits is highly
flammable.] Then apply the solution using a plant spray bottle,
brush out and allow to dry. This prepares the water clay for
contact with most mold rubbers. If the water clay is completely
dry, it should be sealed and coated with release as for terra cotta.
Pol-Ease 2300 Release Agent must be applied to nearly
every surface before pouring or applying liquid rubber (except
silicones) or resin. It should be sprayed evenly and then gently
brushed out with a dry brush to pick up any excess and to spread
the release over any spots missed by the spray. The brush should
be wiped with a paper towel periodically to prevent too heavy a
coating being left on the surface. Too much release can cause
pinhole defects in the surface of the liquid material poured
against it. The coating of release should be allowed to dry for
about 15 minutes prior to pouring. Silicone-based release agents
like Pol-Ease 2300 may interfere with the cure of silicone mold
materials. When pouring silicones, use Pol-Ease 2350 on
surfaces that the liquid silicone will contact. Consider PolyCoat
as a semi-permanent, dry sealer and release when using
polyurethane rubbers.
If you have any question about the compatibility
between the rubber and the prepared model surface,
perform a test cure on an identical surface to determine that
complete curing and good release are obtained. Some materials
such as sulfur-containing modeling clays and wood knots, inhibit
curing of some rubbers and plastics.
Securely fasten and seal side boards or shells to the
base to prevent leakage. Seal and apply release on all side
boards and shell interiors. Petroleum jelly is excellent for most
non-critical surfaces like these, unless the material gets warm
enough during cure to melt the petroleum jelly. Pol-Ease 2300
Release Agent is more heat resistant, but is not self-sealing, so
surfaces must first be well sealed.
Porous models must be vented from beneath to prevent
trapped air from forming bubbles in the rubber. A hole at least
¼-inch in diameter should be drilled through the base board into
the porous model. The base of the model must be sealed around
the perimeter with Poly Plasticene or glue to prevent liquid
rubber from leaking under the model and through the vent hole.
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 Mold Making Methods 1

Mold Making
MIXING THE MOLD RUBBER

Methods
Have all materials at room temperature (75°F) before
mixing. It can take 24 hours for a 5-gal pail of material to warm
up to room temperature in the winter.
Have all materials and equipment clean and ready.
Time is critical to success. You do not want to go searching for
tools after you have mixed Parts A and B.
Stir individual components before use if recommended.
Some materials separate and will not cure properly if separated
material is used.
Weigh and measure accurately. Mix Ratios Vary! Check Before starting to mix rubber, have all materials at hand
the mix ratios for the specific product you are using. For liquid and at room temperature (75°F).
rubbers, most mix ratios are expressed by weight. Carefully
weigh Parts A and B in proper ratio. Weighing components on A Poly Paddle is an
an accurate scale is a must. Only materials with a mix ratio of excellent tool for hand-
1:1 by volume can be measured by volume. Polytek does not mixing liquid rubber without
recommend trying to measure any other mix ratio by volume. introducing excess air into
Close containers tightly after use. Most materials are the mix. Scrape the sides
usable at least six months to a year after shipment if unopened. and bottom of the mixing
Uncured polyurethanes, epoxies and some silicones react with container thoroughly
atmospheric moisture and, therefore, should be used up as soon several times while mixing.
as possible after opening. Before resealing, Poly Purge™ Dry Gas
Blanket (see p. 63) can be sprayed into open containers to
displace moist air and extend storage life.
Time your actions with a clock. Start timing when you start
mixing. Try to have material poured and in place before half of
the working time has elapsed so there is plenty of time for
Carefully Adhere to Mix Ratios!
bubbles to rise away from the mold surface.
The chemistry of polyurethanes,
Mix well, but avoid whipping air into the mix. Scrape the
sides and bottom of the mixing container thoroughly several silicones, and epoxies must add up.
times while mixing. A Poly Paddle is invaluable for good
mixing. Sometimes, to insure that no unmixed material is Unlike polyester resins, the recommended mix ratio
clinging to the sides or bottom, the mix can be poured into a of polyurethanes, silicones, and epoxies cannot be
clean container and mixed again for 1 to 2 minutes before
pouring. For large mixes (i.e., >30 lb), a Jiffy Mixer (see p. 62) varied without causing changes in the physical
on a variable speed drill can be helpful, but care must be taken properties of the cured material. This is because to
not to whip air into the mix or scrape the jiffy mixer blade
against sides and bottom of the container. cure 100 reactive groups of Part A, 100 reactive
groups of Part B are needed. If 100 reactive groups
of A weigh two pounds and 100 of B weigh one
pound, then the mix ratio must be two A to one B
(2A:1B), by weight.

Generally, if excess B is used the cured plastic will

Avoid being rushed. Careful
be softer. If excess A is used the plastic will be
planning allows for a deliberate harder. But off-ratio mixes can cause other
problems, such as no cure at all, dimensional
pace without making mistakes. instability, or short storage life of the cured rubber.

13
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 1 Mold Making Methods
Mold Making

APPLYING THE MOLD RUBBER

Methods

Most often liquid mold rubber is poured over the model surface.
With the development of Polygel products, however, applying
liquid mold rubber to the model surface by brushing or spraying
is becoming increasingly common. No matter how the liquid
rubber is applied, one key is to avoid air entrapment. For poured
molds, the liquid rubber should be poured in a steady stream
into one corner of the mold box, allowing the liquid to flow over
the model surface pushing air out ahead of it. In some cases,
where there is exceptionally fine detail, some moldmakers feel
that applying a small amount of mixed rubber to the surface and
brushing or blowing it into the detail with low pressure air Mold rubbers are typically applied
to a model by pouring, brushing,
before pouring the bulk of the mix helps to ensure that the liquid
or spraying. Liquid mold rubbers
pushes all the air out of the crevices. Caution must be taken that
with thixotropic properties are
brushing does not actually push the liquid through the film of ideal for brush and spray
release agent on the surface, causing sticking, or that release application. Think Polygel®.
does not float to the top of the brushed liquid, preventing

How Much Liquid Rubber Do You Need?

Poured Block Mold - Box Shape Poured Block Mold - Cylinder Shape
3
1. Calculate the volume of the box in cubic inches (in ). 1. Calculate the volume of the cylinder.
V=lxwxh where: l = Length V= π x r2 x h where: π = 3.14
w = Width r = Radius (½ diameter)
h = Height h = Height
e.g., 10 in x 5 in x 5 in = 250 in3 e.g., Using a 10-in tall section of 5-in diameter PVC pipe:
2. Estimate the volume of the model. 3.14 x (2.5 in x 2.5 in) x 10 in = 196 in3
e.g., 8 in x 3 in x 3 in = 72 in3 2. Estimate the volume of the model.
3. Subtract the estimated volume of the model from the e.g., 8 in x 3 in x 3 in = 72 in3
volume of the box. 3. Subtract the estimated volume of the model from the
e.g., 250 in3 - 72 in3 = 178 in3 volume of the cylinder.
4. Use specific volume data (refer to Technical Bulletin for e.g., 196 in3 - 72 in3 = 124 in3
specific product) to convert the volume to quantity of 4. Use specific volume data to convert the volume to quantity
liquid rubber needed in pounds. of liquid rubber needed in pounds.
e.g., Using specific volume of Poly 74-30 Liquid Rubber e.g., Using the specific volume of Poly 74-30 Liquid Rubber of
(27.5 in3/lb): 27.5 in3/lb:
178 in3 ÷ 27.5 in3/lb = 6.5 lb Rubber 124 in3 ÷ 27.5 in3/lb = 4.5 lb Rubber

Note: For the hypothetical model above, far less liquid rubber is needed for the cylindrical mold. Choose your containment area carefully.

Brushed/Sprayed Blanket Mold Poured Blanket Mold

1. Estimate the surface area of the model. Depending on the
complexity of the model, this can be difficult and it may be
necessary to consider a model in sections and add up all surface
areas. If the model is basically rectangular, use the surface area
equation for a rectangle; if cylindrical use the surface area
equation for a cylinder (A = 2πr2 + 2πrh).
2. Multiply the surface area by the thickness of the blanket mold
(usually 0.25 in to 0.38 in) to determine the volume of liquid
rubber needed.
3. Use specific volume data to convert the volume to quantity of
liquid rubber needed in pounds
Poured blanket molds are usually made by covering a model with clay,
making a shell, removing the clay, and filling the area once filled by
clay with liquid rubber. Therefore, the volume of clay equals the
volume of liquid rubber needed. Using the weight of the clay, calculate
its volume by multiplying by its specific volume. Divide the volume of
clay by the specific volume of the liquid rubber to get the weight of
rubber needed.
e.g., If a 2-lb block of clay was removed from the model:
2 lb x 18.4in3/lb = 36.8 in3 clay
36.8 in3 x ÷ 27.5 in3/lb* = 1.3 lb Poly 74-30 Rubber
* Specific volume of Poly 74-30 Liquid Rubber

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adhesion between the poured material and the brushed material.
For more information on applying liquid mold rubber by brush
or spray, refer to Polygel product information (see pp. 36-37).
If a super smooth mold back is desired, a light spray of Pol-Ease
2300 Release Agent on the top surface of the liquid just before it
gels breaks most of the surface bubbles.
CURING THE MOLD
Cure at the same warm temperature that all your materials were
when mixed. Temperatures below 65°F lengthen the time
required for proper curing and may spoil the cure of some
materials. Placing the poured mold or casting in a warmer area
than the materials were when they were poured, can cause
problems because changing temperatures while the material is
setting can cause bubbles or distortion.
Check product technical bulletin for proper cure time. Demold
carefully as the material is still more tender than it will be a few
days later. Bending or forcing a material while it is still only
90% cured can cause distortion that may not recover.
USING THE MOLD
More rubber molds fail due to poor handling than by wearing
out. Proper design, careful handling and attention to detail
prolong mold life.
When casting plaster, wet the rubber mold with Pol-Ease Mold
Rinse or a 1% detergent (e.g., Ivory Liquid) solution in water
before pouring the plaster. Wet the mold by dipping or spraying.
Pour the plaster on the wet surface. [Note: Detergent is
chemically different from soap. Do not use soap -- Ivory Liquid
is a detergent.]
When casting plastics in polyurethane or silicone molds, first
coat the mold with a release such as Pol-Ease 2300 Release
Agent. Release agent is not always needed in silicone molds.
Spray a light even coat of Pol-Ease 2300 on the mold surface
and then carefully brush the surface with a clean, dry brush to
pick up any excess and cover any missed spots.
PVA is a barrier to migration of plasticizers and chemical attack
by harsh casting resins. Poly-Fast 72-40 rubbers contain
plasticizers that can soften resin surfaces producing soft or
sticky castings. If resins are to be cast in 72-40 molds, first coat
the mold surface with PVA and allow to dry, then lightly spray
with an even coat of Pol-Ease 2300. This surface treatment
often acts as a barrier to the plasticizers. PVA can be washed off
castings with soapy water. PVA also prolongs the life of
polyurethane molds when casting polyester resins.
For long mold life, avoid exposing rubber molds to strong
solvents, oils or cleaners. Sprayed release agents reduce solvent
exposure as compared to brush application.
www.polytek.com
Mold Making Methods 1
Mold Making
Methods
This blanket mold of a
baluster is stored
properly in its mold
shell. The thin mold of
PlatSil® 73-45 is
supported by a firm
shell made from Poly
75-80 Liquid Rubber.
STORING THE MOLD
Proper storage of molds cannot be overemphasized and is the
key to extended “library life” -- the time that a mold remains
useful after storage. Some rubber molds, if stored properly, can
have a library life of ten years or more.
Store molds in their original, undistorted shape. Molds should
be left in the mother mold, mold box or on a surface that causes
the least distortion possible. If rubber is left in a distorted shape
for any length of time it can take a permanent set and may never
recover to its original shape.
If a blanket mold is stored in a mother mold/shell made of
porous material, such as bare plaster, the shell surface that
contacts the mold must be sealed (e.g., with shellac). Sealing the
shell prevents it from absorbing oils from the mold rubber
which, in turn, can cause mold distortion.
Do not allow molds made of one type of rubber to remain in
contact with molds of other rubbers as migration of oils or
plasticizers from one to another can cause swelling, shrinkage,
or distortion.
Poly-Fast 72-40 molds may soften over a period of 2-4 years.
TinSil silicone molds may embrittle (i.e., lose tear strength and
elongation) over a similar period. These mold materials should
not be selected if long library life is required.
Molds should be stored in a cool, dry area and out of the
sunlight, which can degrade the surface.
Colors for Polytek Products
Most Polytek Liquid Rubbers & Plastics can be colored with
the use of proper dyes or pigments. PolyColors, reactive liquid
dyes available from Polytek in red, green, yellow, blue, brown
and black, can be used in most Polytek polyurethane
products. In addition, PolyColors can be added to certain
silicones in small concentrations. Polyurethane rubbers and
plastic can be lightly tinted or made vibrant and dark in color
by using PolyColors up to 3% by weight of the total liquid mix.
PolyColor Brown is excellent for creating a base color when
making cold cast bronze parts. PolyColor Black can be used
to make even the whitest plastics true black. Since PolyColors
are dyes, not pigments, they mix in easily and do not settle in
the liquid rubber or plastic when properly mixed. Use
PolyColors individually or in combination to make any color
imaginable. For product information, see p. 61.
15
 1 Mold Making Methods
Mold Making
Methods
CASTING & FINISHING
For simple solid casts, the flexible mold and shell (if required)
are positioned so the opening is level and release agent, barrier
coat or rinse is applied, if necessary. The casting material is
poured right to the top edge, vibrated if necessary and allowed to
cure. Most casts should be removed as soon as they are
adequately set, since longer residence times can damage some
mold materials.
Use of vacuum or pressure (see box below), brushing, spraying
or heated molds are all helpful techniques to eliminate bubbles
and achieve perfect casts of highly detailed parts, but simple
pours are often adequate.
Trim and touch up, is easiest while the casting is warm and is
best done just after demolding. Remove release agent prior to
VACUUM & PRESSURE CASTING
Perfect Castings Made Easily!
Although many excellent bubble-free molds and castings are
made with Polytek rubbers and resins every day, trapped air
bubbles create the most common defects. Proper use of
vacuum or pressure can eliminate bubbles from some kinds of
castings and molds and is often cheaper and easier than you
might think. The following applies only to non-porous molds
and models -- porous materials such as wood and plaster do
not lend themselves to use of vacuum and pressure.
Vacuum
Using vacuum to pull air bubbles out of mixed liquid rubber or
resin can often be very helpful. Place the container of mixed
liquid rubber or resin in a vacuum chamber and draw about 28
inches mercury so that the largest air bubbles rise to the
surface. You must perform degassing while the mix is still
liquid. Do not attempt to “vacuum degas” Polytek rubbers or
resins with short work times -- this can result in creating more
bubbles. Some liquids rise 2 to 3 times their original volume
during degassing, so use a container with adequate head
space. Once degassed, the liquid should be poured carefully so
that air is not reintroduced into the mix.
Simple vacuum chambers can be constructed from pressure
pots as well as from sturdy commercial cooking pots. It’s best
to have a transparent cover. Vacuum pumps can be purchased
from laboratory equipment dealers. A vacuum pump that is too
small with insufficient capacity can be a frustration. You may
find your material gelling before it is free of bubbles. Buy a
large enough vacuum pump that will get down to maximum
vacuum quickly so you can degas and pour before your mixed
material thickens or gels. A Welch Model 1397 can often be
purchased from equipment dealers for ~$3,000 new or ~$1,500
used. It pulls 17.7 CFM and works well with a 40-quart pot.
16
painting by detergent washing. If a prime coat is desired on the
cast part, a barrier coat can be sprayed on the mold before
casting. Paint enhances and protects plastic castings and is
necessary for best exterior durability.
CLEANUP
Tools should be wiped clean with paper towels before the rubber
cures. Casting plastics are extremely difficult to remove from
tools once cured. Be sure to clean tools as soon as possible.
Denatured ethanol is a good cleaning solvent, but it must be
handled with extreme caution owing to its flammability and
health hazards. Work surfaces can be waxed or coated with Pol-
Ease 2300 Release Agent so cured rubber and plastic can be
removed.
An alternative to a traditional vacuum pump is a venturi vacuum
pump from Vaccon Vacuum Products. This device is attached to
a vacuum chamber and an air compressor. The high volume air
from the compressor flows past the double venturi, creating a
negative pressure area, which in turn evacuates the chamber. For
some applications, the venturi pump is a less expensive and
effective option. For more information, go to www.vaccon.com.
Pressure
Using pressure to eliminate bubbles can be even more useful.
The process is like reversing the opening of a bottle of soda.
When pressure is applied to liquid rubber or resin, small
bubbles are forced into solution and disappear. To accomplish
pressure casting, pour the resin or rubber and place the whole
mold in a pressure pot before the material begins to set. Fasten
the lid and pressurize to ~60 psi with compressed air or
nitrogen. Allow the cure to take place under pressure. You will
be amazed with the results.
Inexpensive pressure pots typically used by spray painters are
available from paint supply stores and industrial supply houses
such as Grainger.
Caution: Vacuum and pressure systems can be dangerous. If
you have any questions about the construction or operation of
your vacuum or pressure system, consult a qualified engineer.
Never use glass parts
unless they are
certified for the
purpose.
Welch Model 1397 vacuum pump with
a 40 quart pot and lid made with
Poly-Optic® 1410 Clear Casting Resin.
(610)559-8620 • (800)858-5990

POURED MOLDS
One-Piece Block Mold
To make a poured block mold the model must be securely
fastened (e.g., screwed or glued) to a base board. Kitchen
countertop sink cut outs make excellent base boards. If the
model is porous, a vent hole should be drilled through the
baseboard to the model to allow air to escape. Sides of the mold
containment area must be positioned and sealed to the base
board (e.g., with plasticene or hot melt glue) so that liquid
rubber cannot leak out. If the mold will be used without being
placed in a box for support, then be sure to position the sides far
enough from the model such that the rubber mold will be thick
enough that it will not deform when it is full of casting material (at
least 0.5-inch thick). Sometimes a strap is placed around the finished
mold box to ensure that it all holds together. Once the model and the
Cut Block Mold
A block mold can be cut when cured to make a split or multi-
piece mold. With some models, the mold must be cut to allow
for removal of the model. Sometimes the cut is simply a single
slit up one side of the mold, while in other cases a single-piece
block mold can be cut into multiple pieces to create a complex
multi-piece mold. In either case, after the model is removed, the
mold is reassembled by carefully lining up the seams and
usually returned to its box to hold it together before casting
material is poured into the mold.
For a successful cut block mold, the key is in the cutting. First,
select a rubber with an appropriate hardness for cutting (i.e.,
Poly 74-30, soft Shore A30). Next, carefully evaluate where the
cut(s) will be made (i.e., possibly up the back of the head, not on
the face) and how many cuts are required. The cutting locations
Split Block Mold
This head mold is
cut from a cylinder of
Mold cured rubber. The
Strap containment area is
Rubber
a piece of PVC pipe
sealed to a base-
board with plasticene
Model or hot-melt glue.
After the rubber
cures, the pipe is
removed from the
base and cut with a
saw to remove the
mold. The rubber is
cut with a mold key knife in a predetermined location to make a
slit that allows for removal of the model. To avoid damaging the
model, the first cut should not go completely though to the
model, but rather the final cut through is made with a razor.
When casting, the seam is carefully realigned and the mold is
strapped together. The mold is inverted and casting material is
poured into the opening.
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Mold Making Methods 1
Mold Making
Methods
Poured mold rubber
Sealed and released model
Screw model to base Vent hole
base and sides of the box are properly sealed and released, slowly
pour liquid rubber directing the flow to the bottom of the box and
being careful not to trap air bubbles as the liquid rises. The rubber
should be at least 0.5 inches above the highest point on the model
(mark the mold box before you start pouring liquid rubber).
should be decided before the mold rubber is poured, marked on
the mold box and then transferred to the cured rubber mold. To
cut the mold, use a mold key knife (see p. 62), which has a sharp
blade with a groove that creates a tongue and groove effect in
the cut rubber. This makes reassembling the mold with the
seams properly aligned possible. Vents and pour holes can be cut
or drilled into the cured rubber, or can be formed with rods or
plasticene prior to pouring the rubber. When casting, cut block
molds are reassembled and typically placed back into the
containment area with the pour hole at the top for filling with
casting material.
Sometimes, block molds poured as one piece are the fastest to
make even for oddly shaped models; but they require more
liquid rubber than blanket molds. Making quality, multi-piece
block molds requires considerable practice and expertise.
Multi-Piece Block Mold
Chunk cut out to
remove ears
Vent
Chunk cut out to
release front end
Plug cut out from between legs Split to remove tail
This horse mold is cut from a single block of mold rubber. After
pouring, curing and cutting the mold, it is reassembled and
placed back into the mold box upside down for casting. Casting
material is poured through the feet. As an alternative, the mold
of the horse model could be made as a blanket mold poured into
a pre-constructed shell -- this would mean easier cutting of the
thinner blanket mold and using less mold rubber.
17
 1 Mold Making Methods
Mold Making
Methods

POURED MOLDS (CONT’D) 1 2 positioning key

mold rubber

Block Mold Poured in Two Pieces

A block mold can be made by pouring two pieces of the mold
separately. First, one portion of the model is embedded in clay
clay mold rubber
up to the desired parting line. Then liquid rubber is poured over
the properly prepared, exposed portion of the model (1). After First pour Ready for second pour
the rubber cures, the clay is removed and release agent is applied
to the other side of the model and the cured rubber surrounding 3 vent pour hole vent
it. Rubber is then poured over the second half of the model (2). Mold ready for
Once cured, a pour hole is cut through the rubber mold and, if casting
necessary, vent holes are drilled through high spots in the mold
to eliminate the possibility of trapped air bubbles. The mold is
repositioned in its box and is ready for casting (3).

BLANKET MOLDS The shell is made overtop of the clay usually by brushing on
liquid plastic. Plastic mold shells are lightweight and durable
Poured Blanket Mold and are typically made of Polygel Plastic or another liquid
plastic (e.g., 15-6 or 1512X) thickened with an additive (e.g.,
Generally, to make a poured blanket mold, the model is covered
Poly Fiber, see p. 61). The first section of the mold shell is built
with clay and the mold shell is built over the clay-covered
up against the clay flange. When the first section of shell is hard,
model, then the clay is removed and the liquid mold rubber is
the clay flange is removed, wax and then release is applied to
poured in the void left by the clay.
the edge of the first shell section and the second section is built
First the model must be properly prepared (e.g., sealed and against the first section for a perfect keyed fit of the shell
released) and mounted. Then the model is covered with plastic sections.
wrap to protect it before the clay is applied. The clay blanket is
To make the rubber mold, the clay and plastic wrap is removed
formed around the model and must fill-in any undercuts so that
from the model and then rubber is poured into the shell filling
the mold shell cannot lock to the rubber mold. Since the shell is
the void left behind. The rubber mold can be poured in one piece
often made in two (or more) pieces, the clay is formed with
and cut with a mold key knife after curing. Or, for a two-piece
protruding flanges, which act as parting lines for the shell. In
mold, half of the clay is removed and rubber is poured in the
fact, since the rubber replicates the clay blanket exactly, parting
void along half of the model. After the rubber cures, clay on the
or cut lines should be delineated in the clay for transfer to the
other half is removed, release is applied to the model and cured
rubber. Sometimes “snaps” are placed along the clay blanket so
rubber, and liquid rubber is poured into the void along the
that the rubber mold will “snap” into position in the mold shell.
second half of the model (see story with photos on pp. 22-23).

Cover the model with clay, then build the mold shell. Then pour liquid rubber into the shell.
Shell Clay flange Shell Clay plug
Liquid rubber Shell parting line
(1st half) with groove to make
pour hole
Clay in shell Mold strap
Snaps
Vent

Model Vent

The prepared model is protected with a covering of plastic wrap

and then a clay blanket (~0.5-inch thick) is built over the model.
The shell is made over the clay by brushing on liquid plastic. The
shell plastic is first applied to one half and cured. Then the clay
flanges are removed and release agent is applied to the exposed
plastic and the second half of the shell is built up to the first half.
After the clay is removed, liquid rubber is poured into the void.
When making a one-piece or cut mold, all of the clay is removed
and the entire space is filled with rubber. If necessary, the cured
rubber is cut to remove the model.

18
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 Mold Making Methods 1

Mold Making
Methods
Brush-On Blanket Mold in the rubber mold that can lock the shell onto the rubber when
A brush-on blanket mold is made first, then the shell is made there is a casting/model inside the mold (see box).
over top of the cured mold for support. Some one-piece blanket The parting line for the rigid shell is defined with a clay (i.e., Poly
molds are simply peeled off a low-relief or pyramid-shaped Plasticene) flange applied over the mold. A groove or depressions
model (“sock” mold). But, often it is necessary to create a seam should be made in the clay where it contacts the shell material to
or cut a split in the mold to allow for removal of the model and create good locking and positioning of the shell halves. The mold
castings. To create a parting line in the blanket mold, thin shims shell is built one section at a time against the release coated rubber
(e.g, aluminum flashing or stiff plastic sheet) are positioned on mold and clay flange. When one section of the shell is complete,
and securely fastened to the model. In lieu of shims, rubber can the clay is removed, Vaseline or butcher’s wax is applied to the
be brushed thick enough in areas so that the cured rubber can be exposed shell followed by a release agent, and the next shell
cut to permit demolding. This technique is helpful for masters section is built against the first. The two halves of the shell
with “through holes” that can lock the rubber mold to the master compress the rubber flanges along the mold opening together
(see pp. 20-21). making a good seal so that liquid casting material cannot leak out.
If needed to prevent trapping air bubbles during casting, vents
First, the model is prepared for making the blanket
are formed in the mold by neatly fastening thin straws or rods to
mold. Then thixotropic mold rubber is brushed on.
the model. Remember, neater fastening means less cleanup of
the casting. After the model, shims and vents are coated with The model is prepared (i.e.,
release, liquid rubber is brushed on. sealed and released) and
securely mounted to a base.
Sometimes with large models, it’s a good idea to create “snaps” A vent is drilled through the
or keys on the rubber mold to hold the mold in place in its shell. base to release air trapped
The shell may need to be more than one piece in order to allow in the model. Thin shims are
removal from the rubber blanket mold. There can be no undercuts placed along the model and
in spaces formed under the
Shims legs and arms. The shims
Dealing with Undercuts form a parting line in the
brush-on rubber blanket
When making a brush-on blanket
Brushed-on rubber mold. Once the shims are
mold, all undercuts in the model
secure, the rubber is
must be eliminated before the mold
brushed on in several coats
shell is made. Typically, undercuts Vent
to ¼- to ½-inch thick.
are filled with mold rubber or another
filler material -- even air. Sometimes Filled
the filler must be compressible so that space
the mold can be removed from the Model
model. A hollow bladder can be After the rubber cures, the rubber-coated model is
formed by bridging the undercut area prepared for construction of the mold shell.
with a piece of plastic wrap pressed into the previous layer of A clay flange is formed
Rubber-Covered
rubber. Then another coat of rubber can be brushed overtop of Model around the model to define
the plastic wrap. If more support is needed. the undercut can be Clay Flange the parting line of the rigid
filled with a material such as soft foam then covered with liquid mold shell. Depressions are
rubber. made in the clay that will
In lieu of filling undercuts, a flexible mold shell can be built form “snaps” in the mold
instead of the standard rigid mold shell. A flexible mold shell shell to help properly lock
(e.g., made of Poly 74-30 rubber) can be removed from simple the mold shell halves
undercuts in the blanket mold and can sometimes alleviate the Snaps together. In addition, rubber
need for a multi-piece shell. snaps can be placed on the
Flexible 74-30 A soft, polyurethane rubber rubber mold so that the mold
Rigid shell
mother mold
(e.g., Poly 74-30) can be snaps to the mold shell. The
poured over a release first half of the rigid mold
Brush-on
mold coated blanket mold shell is built up to the clay
enclosed in a simple box or flange. Then, the clay is
rigid mold. Although this removed and the second half
option may be more of the shell is constructed.
expensive since it uses When complete, the two
more rubber, it can save on halves of the shell compress the rubber along the mold opening
labor. to make for a good seal along the mold opening.

19
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 1 Mold Making Methods
Mold Making
Procedures - Brush-On Mold
Methods
Making a Brush-On Blanket Mold with a Plastic Shell
The following example details the procedures involved in
making a brushed mold. The rubber that has been chosen is
Poly 74-20, a soft, stretchy, 1A:2B by weight mix ratio,
polyurethane liquid mold rubber. Of course, there are many
variations to this technique and several choices of rubbers. We
could have chosen to make a one-piece brushed mold with
shims similar to what is shown on page 19. We just as easily
could have made a two-piece mold where we need no cuts to
remove two separate halves of the rubber mold.
This example specifically demonstrates how to create a one-
piece brushed mold without shims, which requires cutting a
seam in the rubber to remove the master and subsequent
castings. The master, shown in Photo 1, is made of a non-
porous, polyurethane plastic, EasyFlo 60. As with all sealed,
non-porous masters, they must be sprayed with a silicone
release such as Pol-Ease® 2300 Release Agent (when using
polyurethane liquid rubber) and brushed with a clean, dry brush
to insure uniform distribution of the release. Care is taken not to
spray too much release since brush marks can be left behind and
picked up in the finished mold. Also, excess release can be
accidentally pushed around when brushing liquid rubber
resulting in delamination between coats or unwanted surface
texture.
In order to make the mixed Poly 74-20 liquid rubber thixotropic
so it clings to vertical surfaces, Poly Fiber II or Cab-O-Sil®
must be added. In this example, Cab-O-Sil is added in small
amounts (Photo 2) and the liquid is carefully folded over to wet
the powder (so it doesn't come out of the cup), then it is
whipped into the rubber to a creamy, uniform consistency. Only
a slight amount of thickening is desired in the first coat of
rubber so all surface detail is captured without trapping bubbles
at the mold surface. Photo 3 shows a thin, first coat of lightly
thickened Poly 74-20/Cab-O-Sil being applied with a China
bristle brush. After the first layer of rubber gels enough to be
undisturbed by the next coat (~45 min - faster with Part 74 Part
X), a second coat of slightly thicker (a little more Cab-O-Sil
used) 74-20 is brushed over the first coat (Photo 4) and allowed
to gel. Before Cab-O-Sil is put into the rubber to create the mix
used for the third layer, a little unthickened Poly 74-20 is
poured into a PlatSil® 71-20 silicone mold to make long 1-inch
by 1-inch strips (Photo 5) for creating a thick rubber flange that
will be placed into the freshly gelled third coat of rubber to
define the location of the seam line. Notice that this model has
several "through holes" (between the arms and the legs) that
need to be filled completely with liquid rubber to provide a
thick enough section of rubber which will be cut when cured to
remove the original. This third layer is done with an even more
thixotropic, non-sag mix of 74-20 and Cab-O-Sil (Photo 6).
20
When this layer is
complete, the freshly
gelled strip of Poly 74-20
rubber is removed from
the 71-20 silicone mold
and positioned against
the mold where the seam
line will be cut once the
mold cures (Photo 7).
A final coat of lightly
thickened rubber is
applied after the prior
coat gels to seal in the
seam line strip and to
make a smooth outer
coating, which makes the rubber mold more attractive and fit
better into its rigid support shell (Photo 8). Once the rubber
mold cures (overnight, or later that day if 74 Part X accelerator
is used), it is trimmed at the base and a clay wall is built up to a
line that will define the parting line of the two shell sections
(Photo 9). Since the shell will be rigid, there can be no
undercuts that will lock it onto the rubber mold. More
complicated models may require more shell sections to insure
that they can be easily removed. Notice the keys/grooves in the
clay wall that will insure proper registration of the shell halves.
Butcher's wax is brushed over the rubber mold, allowed to dry
for 10 minutes, then sprayed with a coat of Pol-Ease 2300
Release Agent.
To make the shell, Poly 1512X Polyurethane Liquid Plastic is
mixed together (1A:1B), then Poly Fiber thickener is added to
make it thixotropic (Photo 10). Poly Fiber is added until the
resulting mix clings to the side of the mixing container. The
thickened 1512X is applied ~¼-inch thick and allowed to cure
~60 min (Photos 11). The clay wall is removed, butcher's wax
and Pol-Ease 2300 applied to the other side of the mold and
against the first shell section and the above procedure with
1512X is repeated. The completed shell is drilled, bolted and
edges sanded for easier handling (Photo 12).
When the shell is removed, a mold key knife is used to cut a
notch in the rubber the length of the seam from head to toe. A
sharp scalpel is then used to cut the rest of the way to the
master. As the rubber is peeled open, cuts are made between
the legs and arms as needed to remove the original. Cutting in
these areas is done using a series of short, jagged, zig-zag cuts
in order to create a series of tiny keys that keep the seam
registration exact (see photo above). The finished mold and
shell are now ready for production!
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 Mold Making Methods 1

Mold Making
Procedures - Brush-On Mold

Methods
Photo 1 Photo 2 Photo 3 Photo 4

Photo 5 Photo 6 Photo 7 Photo 8

Photo 9 Photo 10 Photo 11 Photo 12

21
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 1 Mold Making Methods
Mold Making
Procedures - Poured Blanket Mold
Methods
Making a Two-Piece Poured Blanket Mold in a Plastic Shell
This page details the step-by-step production of a flexible rubber
mold and plastic mother mold of the 19-inch-tall, 19th-century
marble statue entitled Ice Skater by Gori Nello.
Deciding on the Type of Mold
Openings under the arms and legs presented typical difficulties
that influenced the selection of the type of mold to be
constructed. The moldmaker decided on a blanket mold, poured
in two halves into a constructed shell, because pouring yields
better detail with less trapped surface bubbles. A poured mold
also eliminates undercuts more easily than a brush-on mold. A
double pour, with carefully selected parting lines, eliminates the
need for shims (see p. 18), which would leave flashing to be
chased, and cutting, which would be required with a single-pour
mold and could scratch the valuable sculpture.
Selecting the Materials
Poly 74-30, a two-part, 1:1 mix polyurethane liquid rubber, was
used for the mold since it is low cost, easy to mix and pour,
flexible (Shore A30), and has good longevity. Poly 74-30 molds
work well for casting plaster, cement, wax or resins.
The mold shell was made with Poly 15-6, a 1:1 mix liquid
plastic with a 5- to 7-minute working time. The plastic shell is
lightweight and durable. [Note: Alternative materials for making
mold shells are plaster reinforced with hemp or burlap, Polygel®
Plastic-75, or Poly 1512X with Poly Fiber II. The larger the
shell, the more important it is to use lightweight shell materials.]
Preparing the Statue
First, the marble statue was fastened to the base with Polypoxy®
Quick Stick Adhesive. The base was formica-coated particle
board from a countertop sink cut-out. To protect the marble from
the oils of the release agent, a thin layer of PVA (polyvinyl
alcohol) solution was brushed directly on the marble. (PVA
solution washes off with warm water.) After the PVA dried, a
liberal coat of release agent was sprayed over the model and
brushed out with a dry brush to pick up any excess and to work
release into any areas missed by the spray (Photo 1).
Building the Mother Mold
Next, the statue was wrapped in plastic wrap to keep it clean
(Photo 2). Then, a ¼-inch blanket of Poly Plasticene (oil-based
clay) was hand pressed onto the plastic wrap. To make the clay
uniform thickness, warm Poly Plasticene (~130°F) was placed
between 2 equal height wood strips and rolled flat using a PVC
pipe. The height of the wood strips (¼- to ½-inch) determines
the thickness of the clay blanket. All undercuts were filled with
Poly Plasticene so the shell could be easily removed.
Shims of thin aluminum flashing were placed in the clay to
create parting lines for the shell (Photo 3). These are the only
shims needed with the double pour process to make this mold. A
channel was built around the edge of the clay to cause the rubber
mold to lock into the shell.
22
To build the shell for the
first half of the mold, Poly
Fiber was stirred into mixed
Poly 15-6 Liquid Plastic
until it was the consistency
of cake frosting. Then, the
thickened resin was laid on
the first half of the clay in a
manner similar to icing a
cake. [Note: When making
larger shells, multiple mixes
of resin and Poly Fiber can
be patched against each
other to cover the entire The original marble and plaster
surface.] After the first half and plastic reproductions made in
of the shell cured (~4 hours), the Poly 74-30 blanket mold.
the aluminum shims were
removed and paste wax (i.e., Butcher’s Wax) and then release
agent were applied to the first half of the shell (Photo 4). The
second half of the shell was built against the first half in the
same manner (Photo 5).
Pouring the Rubber
One-half of the plastic shell was removed along with the clay
blanket beneath that half of the shell. Keys (tongue-and-groove
impressions) on the second half of the clay were made in order
for the two halves of the rubber mold to “key” or lock together
(Photo 6). Vent holes were drilled in the shell with a ¼-inch drill
at each high point where air would be trapped (Photo 7). The
shell was thoroughly coated with release agent, replaced and
positioned for pouring the rubber. Poly 74-30 was mixed and
poured into the space within the shell where the first half of the
clay had been. When pouring the rubber, the model was at the
bottom of the cavity so the air bubbles would rise away from the
model surface. As liquid rubber appeared at the vent holes, they
were plugged with plasticene clay (Photo 8).
After the rubber cured overnight, the shell and clay on the
second half was removed and release agent applied to the model
and the face of the cured rubber parting line (Photo 9). The shell
was reassembled and rubber was poured into the shell to cover
the model’s second half.
After the rubber cured, the shell halves were separated by
tapping wood wedges into the seam, gradually forcing open the
shell to reveal the complete mold (Photos 10 and 11).
The Casting
Plaster was poured into the mold to clean and check the mold.
Finally, release agent was applied, brushed out and the mold was
properly positioned in its shell. Poly 15-3X, a mineral-filled,
fast-setting polyurethane casting resin, was poured into the mold
(Photo 12). The final casting was demolded in less than an hour.
The excellent reproductions are shown with the original above.
(610)559-8620 • (800)858-5990
 Mold Making Methods 1

Mold Making
Procedures - Poured Blanket Mold

Methods
Photo 1 Photo 2 Photo 3 Photo 4

Photo 5 Photo 6 Photo 7 Photo 8

Photo 9 Photo 10 Photo 11 Photo 12

23
www.polytek.com
 1 Mold Making Methods
Mold Making

Applications - Sculpture & Foundries

Methods

B
ill Hopen, Hopen Studio in Sutton,
WV, uses Poly 74-30 thickened
with Cab-O-Sil® to make a brush-
on mold of his clay “St. Joseph the
Worker.” Three to four layers of mixed
Poly 74-30 are applied at 60- to 90-
minute intervals. The first layer contains
little or no Cab-O-Sil so that air bubbles
are minimized and fine details are
reproduced. More Cab-O-Sil is added to
subsequent layers for faster build up of
the ¼- to ½-inch mold. Twenty-four
hours after the final layer, Hopen builds a
rigid mold shell. The great flexibility of
rubber molds allows for easy demolding
of delicate wax castings. The long mold
life of Poly 74-30 has enabled Hopen
Studio to continue producing castings 10
years after some molds were made. These
molds are made much more quickly than
latex molds and at a fraction of the cost of
Poly 74-30 Liquid Rubber thickened with Cab-O-Sil -- Sculptor Bill Hopen silicone molds. Bill says “I’ve tried them
®

all; Polytek Mold Rubber is the best.” For

sculpture by Hopen call (304)765-5611.

Architectural Restoration

T HR Cast Stone and GFRC of Brooklyn, NY, has restored

many of the most architecturally significant buildings in
New York City. Whether the medium is brownstone,
limestone, terra-cotta, plaster, or stone, the artists, moldmakers,
and casters at THR have reproduced and restored it to match its
original beauty. Newly cast parts made from cast stone, glass-
fiber-reinforced concrete (GFRC), or glass-fiber-reinforced
gypsum (GRG) appear original in every way. THR has used
Polytek products to recreate ornamental architectural elements
in theaters such as Lyric and Ed Sullivan, museums such as the
Metropolitan, and hotels like the Plaza and Ansonia, as well as
churches, schools, and private residences. THR prefers Polygel®
rubbers (see p. 36) for brush-on or sprayed molds that are
created on-site from an element before it is removed from the
building. For work back at the shop, THR often opts for Poly THR Gives New York City A Facelift with Polytek Rubbers
74-45. Once a mold of the original is made, a casting is taken The Ansonia Hotel in Manhattan is just one of the strikingly
and the artists meticulously recreate any eroded or missing ornate buildings that THR has restored. Above, Philip Gallagher
detail, based on other parts of the original still in good shape, of THR displays a Poly 74-45 mold that was used to recreate
historical photographs, etc. Once the master is completed, a aging architectural brackets from a 13th-floor balcony of the
mold and perfect reproductions are cast. Since many Ansonia Hotel. Cast GFRC replacement brackets in the
architectural features repeat on a building, a mold such as this background await installation.
may be used again & again -- no problem for high-performance
rubbers from Polytek.

24
(610)559-8620 • (800)858-5990
 Mold Making Methods 1

Mold Making
Applications - Home Decor

A decorative drapery rod end was cast using EasyFlo 60
Liquid Plastic (see p. 48), a super low viscosity polyurethane
product, filled with bronze powder to create this faux metal
part. The two-piece poured block mold registers nicely due to
keys/snaps, which keep the mold aligned properly during the
casting process. A PlatSil® or TinSil® silicone mold could easily
produce many dozen resin castings or more without the need
for release agent.
Methods
A Poly 15-6 plastic column capital is demolded from a TinSil®
70-11 silicone rubber mold. This rubber is very soft (Shore
A10) and stretchy eliminating the need for seams in the mold
to remove cast parts. The shell was made using Poly LiteCast,
a very low density, pourable polyurethane plastic to reduce the
weight of the shell for easier handling. The column posthole
was made by inserting a plastic pipe as a plug in the 70-11
mold prior to casting.

Props, Displays & Special Effects

PlatSil Gel-10 was used by Gordon Tom Kipp of Studio
Smith of FXSmith in Toronto, One/Mannetron is shown
Canada to make hundreds of with a hollow, rotocast
silicone prosthetic appliances, which polyester alien that was
became the scales worn by
used as a prop in the
Mystique in the blockbuster movie
movie The Roswell
X-Men. Smith modified PlatSil Gel-
10, a versatile 1:1 mix silicone, so Incident. The casting
that it was self-sticking using was made in a two-piece
Polytek's PlatSil Deadener. This brushed-on Polygel® 40
allowed the scales to be removed mold. Rotocasting
and reapplied for each filming equipment made by
session without adhesives. Mannetron was used to
create several dozen alien
A PlatSil® 71-20 silicone rubber figures. Polyvinyl alcohol
mold was made from a gigantic was used as a barrier
fossilized shark tooth to make a coat and the mold was
museum display item. This two- washed in a warm
piece poured block mold is detergent - water solution
keyed extremely well with snaps after several castings to
and a tongue-and-groove remove styrene buildup in
channel to keep the flashing to a minimum. The casting was the mold, which could
made using EasyFlo 120 with 3% PolyColor Black. The liquid eventually damage the
plastic was poured into one half of the mold, then the mold was mold. This process helped prolong the mold life so that after
closed and supported between two small pieces of plywood several dozen castings the mold still looked like new!
with rubber bands, and slush-cast by hand to produce a super
part in 15 minutes.

25
www.polytek.com
 1 Mold Making Methods
Mold Making

Applications - Concrete
Methods

Flexible formliners of every

size and design are routinely
created using Poly 74, 75
and 77-Series Polyurethane
Liquid Rubbers. These Poly
rubbers are tough and
abrasion resistant making
them ideal for the rigors of
repeatedly casting large
concrete parts and panels.
These formliners can be
made to reproduce any
surface texture or design
and can be bonded to Cast veneer stones are made by pouring concrete into rubber
plywood or attached to rigid gang molds such as this one made from Poly 74-44 polyurethane
supports for precast or cast- rubber. Individual stones can be cast simultaneously into multi-
in-place applications. cavity molds then applied to a wall to give the look and feel of real
stone. Flexible formliners/molds can be made of entire wall
sections for extremely large projects.

Poly 75 and 81 Poly 74-45, a

Series Polyurethane popular 1:1 mix,
Liquid Rubbers are polyurethane liquid
used to make rubber, was used to
concrete stamping make a paver mold.
tools and texturing Pavers cast from
skins. These molds made from
stamping tools are liquid rubbers have
made by pouring much better, life-like
rubber about ¾-inch surface detail than
thick onto a pattern those made from
that mimics the rigid molds owing to
design that will be the fact that the
imprinted to the liquid rubber flows
concrete. Patterns readily into all
such as slate, brick, available detail on the master before curing. Hundreds to
irregular flagstone or any custom design including leaves, fossils thousands of concrete parts can be cast from a single mold
and much more turns otherwise boring, flat,concrete pathways, depending upon surface texture, proper selection of mold rubber
driveways and patios into beautifully colored and textured and release agent, and careful demolding.
surfaces.

Polygel® Spray 35 was used to make a mold of this architectural

element. The casting was made from glass fiber reinforced
concrete (GFRC). The Polygel mold was created using a low-
cost (~$4,000) machine designed to automatically meter/mix and
spray the liquid rubber at a 1:1 ratio. The resulting mold is thin
(~3/8-inch thick) so it is very economical and easy to peel away
from complex shapes. Polygel rubber can be brushed for smaller
jobs or sprayed when larger surface area molds are needed.
This mold was sprayed in one continuous process, which took
less than 20 minutes to complete! Polygel Spray 35 cures
enough in 6-8 hours to allow a shell to be applied in the same
day.

26
(610)559-8620 • (800)858-5990
 Mold Making Methods 1

Mold Making
Applications - Concrete

Methods
A decorative An article in Handy
concrete Magazine described
panel was how to use Poly 75-
cast as part of 80 Liquid Rubber to
make thin, low-cost
a building
texturing skins to
restoration
impart a slate
project by
appearance to flat
THR Cast
concrete. These
Stone and
texturing skins were
GFRC of made by pouring
Brooklyn, NY. Poly 75-80 over real
A Poly 74-45 pieces of slate
mold is shown (properly sealed and
being released). Once the
carefully demolded. The thin poured blanket mold was supported first pour gelled, a
by a GFRC shell and wood-framed box displayed in the second pour was
background. made with slightly
less rubber so it
didn't quite flow to
the edge of the
Highway previous pour. Even less rubber was used for the third pour done
sound to make a texturing skin that was thicker in the middle with
barriers are tapered edges. This allowed the thin cured rubber mats to be
becoming overlapped at the edges to make a seamless pattern in the
more popular concrete. A thin Poly 75-80 tool is shown being removed from the
to keep traffic freshly textured surface. With the use of concrete colors and
noise from stains the results are stunning!
residential
areas. Poly 75
Series A Poly Latex 60
rubbers were mold was made to
used to make reproduce this
flexible concrete angel. The
formliners with wildlife images to enhance the visual appeal of mother mold (rigid
the standard ribbed wall panel design. Formliner designs shell) was made
incorporating rock, slate, brick, fossil, wood-texture and other from Poly 15-6
architectural and artistic designs are becoming more common as Liquid Plastic
architects realize the endless possibilities available when flexible thickened with Poly
molds are used. Fiber to make it
brushable. The thin
blanket mold could
also have been made using Polygel® 35 or Polygel 40, high-
Polygel® Spray 50 performance two part brushable rubbers. Latex rubber is a one-
was sprayed onto part mold material, but 15-30 coats of rubber applied over
this larger-than-life several days are required to complete the mold. A Polygel mold
head to make a can be made in a matter of hours! This Angel blanket mold is a
thin, yet durable, one-piece glove mold with no seams, whereas the rigid shell is
mold. With the made in several sections to accommodate numerous undercuts.
right equipment,
this type of mold
can be made
anywhere -- even
If you can pour concrete,
several stories
above street level.
you can pour liquid rubber!

27
www.polytek.com
 1 Mold Making Methods
Mold Making
Applications - Prototyping & Model Making
Methods
Prototype Parts of All Kinds Made with Polytek Liquid Rubbers & Plastics
Larami Limited, headquartered in Mt. Laurel,
NJ, is the originator and manufacturer of the
internationally-recognized Super Soaker® toy
water guns. With engineering and prototype
model development facilities in Whitehouse
Station, NJ, Larami Limited has been using
Polytek’s mold rubbers, such as PlatSil® RTV
Silicones, and casting plastics, such as Poly
15-3X, Poly 1512 and Poly-Optic® 1410, very
successfully to create their new products.
Producing the Prototype
Many different techniques involving numerous
Polytek products are employed in the
production of a unique model or prototype part
such as the Super Soaker. Master models can
be carved from wood, sculpted from clay,
machined from polyurethane board, wood or
plaster using CNC equipment, or created from
a liquid photopolymer using a stereo-
lithography process.
As with any mold making process, it is
important to determine the most appropriate
combination of mold making and casting
materials for the project at hand. If wax
castings are to be made (say for a lost wax
process as is used for making many metal
prototype parts), then a polyurethane mold
rubber such as Poly 74-30 or Poly 74-45 (see
p. 34) may be the best choice as they are most
PlatSil® 71 and 73 Series mold rubbers
are widely used for model making and
prototyping. This two-piece block mold
made of PlatSil 71-35 is used to reproduce
a thin-walled car model. Prototypers cast
dimensionally accurate parts fast using
EasyFlo™ 60 Liquid Plastic (see p. 48).
28
cost-effective and release waxes nicely.
Many times plastic parts are the desired end
result, as in the case of a Super Soaker.
PlatSil® and TinSil® RTV Silicone Rubbers
(see pp. 40-45) are the best choice for casting
polyurethane plastic prototypes. These high-
performance silicone rubbers offer the best
mold life and resistance to damage from
repeated casting with chemically aggressive
liquid polyurethane resins. TinSil 70-25 and
70-39 are popular silicone rubbers for Larami Ltd., originator of the Super
modelmakers since they are lower-cost, tin- Soaker®, uses Polytek’s rubber and plastic
catalyzed systems and have hardnesses that products to make molds and castings for
makes difficult parts easy to demold. When various prototyping projects.
using any tin-catalyzed silicone rubber, be sure
to perform a test cure to insure the alcohol with a super-low mixed viscosity, try
released during the rubber’s cure does not EasyFlo™ 60 Liquid Plastic (see p. 48).
interfere with the cure of the polyurethane Rotational Casting
plastic. If alcohol on the mold surface poses a
An additional use of Polytek fast casting
problem, heating the mold to 200°F for several
plastics at Larami was to rotationally cast the
hours can assist alcohol removal.
large pressure tank prototype for the Super
Any PlatSil rubbers can be used for casting Soaker squirt gun by rotating the hollow tank
polyurethane plastics. PlatSil 71-20 is an easy mold with a small amount of a Poly Plastic
1:1 mix, Shore A20 rubber with a super low such as Poly 15-3X coating all surfaces as it
viscosity and 4-hour demold. For applications set. Poly 15-3X sets in about 15 minutes at
requiring firmer rubber, PlatSil 71-35, 73-45, room temperature, but the silicone rubber
or 73-60 provide excellent tear and suitable mold was heated to hasten the set and
hardnesses. When pouring any one of the demolding time of the Poly 15-3X resin. All
TinSil or PlatSil rubbers over a model, Pol- Poly 15 Series resins can also be accelerated
Ease ® 2350 Release Agent (non-silicone) with a few drops of Poly 15 Part X
should be evaluated as a release. Accelerator. See pages 46-56 for more
Poly Plastics Have Thermoplastic Feel information on Polytek’s Liquid Plastics and
The Poly 15-Series products (see p. 49) offer page 64 for more on rotocasting.
many types and speeds of cure for almost Water-Clear Poly-Optic® 1410
every application. Poly 1512 and 1512X are
Another Polytek polyurethane plastic used by
most popular for prototypers interested in a
Larami is Poly-Optic 1410, a water-clear, low
tough, high-performance product with a
viscosity resin, which can be used for
thermoplastic feel. It has a 1:1 mix, can be
transparent parts such as face shields, toy-auto
easily colored with PolyColors, has low
windshields, windows, headlights and eyes.
viscosity, a fast (5 min) or slow (20 min)
potlife, and very impressive physical
properties when cured. It is non-brittle in thin
sections and has a high tensile strength. It can
be sanded, carved, machined or painted as
Pressure casting can help
needed. Other 15-Series plastics can be used prototypes and model
for lower (Poly LiteCast™, page 54) or higher
density (Poly 15-3X) parts. Poly 15-8 is also makers create perfect,
available for modelmakers interested in
making heat-resistant tools for vacuum-
bubble-free castings.
forming applications. For rapid-casting See page 16.
applications of complex parts requiring a resin
(610)559-8620 • (800)858-5990

Applications - Cast Polyester/Fiberglass Parts
Brush-On Polygel® Molds Used to Cast Polyester/Fiberglass Capitals Polygel 40 was used to cover the fabric and foam. A
Russ Veder, of American Architectural Art, chose Polygel rubbers because
of their ability to be brushed on easily and capture incredible detail. Edon fiberglass/ polyester resin parts were sprayed into the
moldmakers Matt Axel and Bob Mathias agreed, "Polygel was the best mold Polygel mold that was coated with a polyvinyl
rubber we ever used. After casting 10 large fiberglass parts, the mold was
in such good condition, we could have made 50 more."
Poly Latex for Polyester Fiberglass Parts -- Capitol Displays
Poly Latex 60 was brushed on a sculpted resin model to produce this large
blanket mold for a decorative architectural part.
www.polytek.com
Mold Making Methods 1
Mold Making
Methods
Restoration of the Widener Building in Philadelphia
began in the summer of 1990, by Russ Veder, an
expert in architectural restoration and principal of
American Architectural Art. This project required
making detailed flexible rubber molds of the
building's ornate Corinthian column capitals, which
measure 8 feet by 7 feet with deep 24-inch undercuts.
Russ, with subcontractor, Edon Corp., resculpted a
fiberglass duplicate of the aged capital to bring it
back to its original design. The duplicate was used as
a working model to make a Polygel mold that
ultimately produced the 10 fiberglass capitals needed
for the restoration. Fabric reinforcement was pressed
into the wet rubber where needed and soft, flexible
foam was pressed into the undercuts to allow the
shell to be removed more easily. A final coat of
fiberglass shell was made the following day. Cast
alcohol (PVA) barrier coat to protect the mold from
the harsh effects of the polyester resin.
Tony Lorino, Capitol Displays of Nashville, TN,
uses Poly Latex 60 molds to produce polyester and
fiberglass copies of original sculpted models. Poly
Latex 60 is the rubber of choice because of it’s
durability and ease of application. Being a single
component material, Poly Latex 60 is brushed on
without the limitation of a pot life. Ten to twenty
coats are applied, two per day, to build up proper
mold thickness. Gauze is often incorporated into the
latex to lend additional strength to large molds.
Lorino then builds a rigid polyester and fiberglass
mold shell over the latex mold to maintain the shape
of the mold during casting. Poly 15-6 and Poly
Fiber, or Polygel® Plastic-75 should also be
considered for this application. The end result is a
lightweight, high tear strength mold with good
resistance to the swelling caused by polyester resin.
Poly Latex 60 molds allow Capitol Displays to
produce detailed parts with undercuts that would be
impossible with rigid molds.
29
 1 Mold Making Methods
Mold Making

Applications - Foam Parts & Shells

Methods

Poly 15-3X, 1:1 mix PolyFoam R-8, a 1:1 by

polyurethane plastic, was volume, closed-cell foam,
rotocast to create a thin, makes strong, lightweight
lightweight, hollow casting. castings quickly. PolyFoam is
After the 15-3X gelled in ~5 mixed and poured into a
minutes, Poly 15-6 TinSil® or PlatSil® silicone
polyurethane plastic with 3% rubber mold, which is covered
(by weight) Part 15F Foamer with a lid to pack the foam to a
was poured into the hollow higher density for good mold
15-3X shell while still in the mold. The 15-6/Part F open-cell fill, thicker skin, and better
foam expanded to fill the cavity giving the hollow casting support surface detail. About 20
without adding much cost or weight. minutes later, parts such as
this plaque or pot can be
removed from the mold. A barrier coat, such as Barrier PF, can
PolyFoam R-5, a 1:1 by
be applied to the mold to prolong mold life and provide
volume rigid foam, was used
primed/painted parts upon demold.
to create a very lightweight
mold shell to support this
brushed blanket mold of Poly PolyFoam R-5 and R-8
74-29 polyurethane rubber. can be used to easily
The shell was made by create parts such as
pouring liquid PolyFoam R-5 these plaques. Since
into an unsealed wooden box built around the cured rubber mold the foams are self-
that was covered with butcher's wax for release. When the foam skinning, the plaques
expanded, it adhered to the box and conformed to the shape of have all the detail of the
the rubber mold. A little foam goes a long way! original.

Hollow Lightweight Castings

Poly 1512X, a 1:1 mix,
pourable, high strength,
polyurethane liquid plastic
was mixed with PolyFiber
thickener to turn the
pourable plastic into a
non-sag, thixotropic mix
that was laid up by hand
into a Polygel® mold of a boulder. A thin face coat followed by a
thicker backup coat were applied to create a total thickness of
approximately ¼ inch. Very little material was needed, so the
resulting casting was lightweight and low cost. A similar hollow
casting could have been made using polyester resin and
fiberglass or glass-fiber reinforced concrete.

This 10-inch tall head was rotocast using

A poured blanket mold made of Poly 74-20 polyurethane rubber
just a few pounds of EasyFlo 120, a 1:1
was made from a chainsaw-carved wooden bear to create
by volume mix, polyurethane plastic that
lightweight duplicates. Notice the thickened seam line in the
is designed for rotocasting (see
back of the mold that was cut with a mold key knife to permit
equipment on p. 63) and slush casting,
easy demolding and minimal seam cleanup. Since this mold is
which is done by hand. If poured solid,
larger, "snaps" or "buttons" were made in the clay blanket which
this casting would weigh and cost much,
ultimately became part of the rubber mold so the mold would not
much more. EasyFlo 120 captures all
flop away from the shell while being rotated in the rotocasting
the detail without thin spots or bubbles.
machine.

30
(610)559-8620 • (800)858-5990
 Mold Making Methods 1

Mold Making
Applications - Statuary & Figurines

Methods
This 12-inch tall These frogs were cast in a
sculpture of a TinSil® 70-25 silicone mold.
mother and child Each cold cast bronze was
was created by Mary made from EasyFlo 60
Smith of Leesport, Plastic with bronze (mix ratio
PA, and was molded 1A:1B:2 bronze, by volume)
at a Polytek Seminar and finished with a different
& Workshop using patina for a unique look.
PlatSil® 71-10 Liquid
Silicone Rubber. The
sculpture was A poured blanket mold was made using PlatSil® 71-20 Liquid
disassembled into Silicone Rubber, a unique, 1:1 mix, 4-hour-cure system, which
two pieces so that can be used to cast any medium. This gargoyle could now be
the child could be cast in plaster,
molded separately concrete or any
from the mother. The pourable plastic
cold-cast bronze using this PlatSil
figurines were made mold. This blanket
by slushing a thin coating of Poly 1512X mixed with bronze mold was poured in
powder around the surface of the mold until it gelled. Then a a single piece, then
dense, low-cost polyurethane plastic (Poly 15-3X) was used as a cut, using a mold
backfill to simulate the weight of a real bronze casting. The key knife, up both
resulting figurines were glued together using EpoxyBond sides to create a
adhesive and felt was applied to the bottom. Faux bronze at its mold which opens
best! like a book.

& More!
The use of Polytek’s liquid mold rubbers
and casting plastics is not just limited to If you have an application you don’t see
the applications described on the past here, call Polytek Customer Service for
several pages! assistance.
Š Candle makers The use of Polytek materials is limited
Š Soap manufacturers
only by the imagination -- may yours be
limitless.
Š Jewelers

Š Taxidermists

Š Forensic scientists

Š Hobbyists of all kinds

Š Inventors

Š & many others

Use Polytek products to make their
creations.

31
www.polytek.com
 2 Polyurethane RTV Mold Rubbers
Polyurethane RTV Liquid Mold Rubbers
Polytek offers several Polyurethane RTV Liquid Mold Rubbers
each formulated to meet various customer applications. Polytek’s
polyurethane mold rubbers consist of a Part A and a Part B that,
after mixing, cure at room temperature to flexible, high-strength,
Polyurethane
Mold Rubber
mold rubbers. Polyurethane rubbers make durable, easy releasing
molds for casting plasters and waxes without release agents, but
when used with proper release agents are also excellent for cast-
ing concrete, epoxy, polyester, urethane and acrylic.
For many Polytek polyurethane mold rubbers, the last two digits
in the product name indicate the approximate Shore A hardness
of the cured rubber. Polytek polyurethane mold rubbers range in
hardness from a very soft A20 to a very firm D45.
MODEL PREPARATION
Porous models, such as wood, plaster, stone, pottery or masonry,
must be sealed, then coated with a release agent. Multiple coats
of paste wax dried and buffed will seal most surfaces. Potters
soap can be used as a sealer for plaster. Lacquer, paint, PVA,
PolyCoat and Pol-Ease® 2350 also work well as sealers for many
surfaces. Models made of sulfur-containing modeling clay (i.e.,
Roma Plastilina) should be sealed with shellac. [CAUTION:
When shellac is used as the sealer, it must be thoroughly coated
with release agent because polyurethane rubbers bond tena-
ciously to shellac. In fact, uncoated shellac may be used to bond
polyurethanes to certain surfaces (i.e., plaster).]
Non-porous models (i.e., metals, plasticene, wax, glazed ceram-
ics, fiberglass, and polyurethanes) and sealed porous models
should be coated with a release agent such as Pol-Ease 2300.
If there is any question about the compatibility between the liq-
uid mold rubber and the prepared model surface, perform a test
cure on an identical surface to determine that complete curing and
good release is obtained.
Porous models must be vented from beneath to prevent trapped
air from forming bubbles in the rubber (see p. 12).
MIXING AND CURING
Before mixing rubber, be sure that both Parts A and B are at room
temperature and that all tools and models are ready to go! Check
product labels or technical bulletins to determine working time
for the product -- some products set fast -- meaning that you must
work quickly.
Many Polyurethane Part Bs require stirring before use. If there is
a “Stir Before Use” label on the container -- be sure to do so.
Mix Ratios Vary! Check the mix ratios for the specific product
you are using. For polyurethane rubbers, most mix ratios are
expressed by weight. Carefully weigh Parts A and B in proper
ratio. [Note: Polygel products can be mixed 1:1 by weight or vol-
ume. See p. 36.]
Weigh Part B (usually the lower viscosity component) into a
clean metal or plastic mixing container. Then weigh the appro-
32
POLYURETHANE MOLD RUBBERS:
AT A GLANCE
Poly 74 & 75 Series - Flexible, high-strength mold rub-
bers for making tough, durable molds. Polytek’s easiest-
to-use and best-selling mold rubbers!
Polygel® Series - Thicken immediately upon mixing
components making these products exceptional for
making brush-on or sprayed blanket molds.
Poly 77 Series - High elongation mold rubber for maxi-
mum mold life in high volume applications.
Poly 81 Series - Firm rubber for making durable molds,
forms or industrial parts.
Poly 72-40 Series- Flexible rubber that performs well
for casting wax and plaster.
Poly GlassRub- Clear, flexible rubber for making cut
molds or casting clear or colored art/decor objects.
priate amount of Part A into the same container. Mix thoroughly.
Hand mixing with a Poly Paddle (see p. 62) is best to avoid mix-
ing air into the rubber. While mixing, scrape the sides and bottom
several times to insure thorough mixing. Pour the rubber as soon
after mixing as possible for best flow and air bubble release.
Vacuum degassing or pressure curing helps to provide bubble
free molds, but is usually not necessary.
Allow the rubber to cure at room temperature, 77°F (25°C). Heat
accelerates the cure - low temperatures slow the cure. Avoid cur-
ing in areas where the temperature is below 60°F (15°C).
Check product labels or technical bulletins to determine appro-
priate cure times. For most polyurethane products, final cure
properties are obtained in about seven days, but most molds may
be used with care after curing for 24 to 48 hours.
USING THE MOLD
Usually no release agent is necessary when casting plaster or
molten wax in polyurethane molds. When casting with plaster,
sponge, dip, or spray the mold with Pol-Ease Mold Rinse and then
pour plaster on the wet mold to reduce air bubbles in the plaster
and aid release. When casting resin, spray the mold with Pol-Ease
2300 Release Agent. For casting concrete, use an appropriate
form release such as Pol-Ease 2650 or 2601 Release Agent.
Exposure to solvent-containing form releases should be kept to a
minimum to reduce likelihood of mold distortion due to shrink-
age or swelling.
After repeated casting with certain resins, plaster and concrete,
molds may shrink or swell since these materials can either extract
oils from the mold or force chemicals into the rubber matrix. The
proper selection of release agent and/or barrier coat can minimize
this effect. If shrinkage becomes evident, a light application of
(610)559-8620 • (800)858-5990
 Polyurethane RTV Mold Rubbers 2
Pol-Ease Mold Dressing can help to restore the mold to its origi-
nal dimensions. For more information on the use of Pol-Ease
Mold Dressing, call Polytek Customer Service.

ADDITIVES
Polytek offers various additives that can be used to vary the prop-
erties of the cured and uncured polyurethanes.

Polyurethane
Mold Rubber
• Softener - For the Poly 74, 75 and 77 Series RTV Liquid
Mold Rubbers, add Poly 74/75 Part C Softener for a lower
viscosity mix and a softer cured rubber. Poly 74/75 Part C
Softener may be added to most other Polytek polyurethane
mold rubbers except Poly 72-40.
• Accelerator - For Poly 74, 75 and 77 Series RTV Liquid
Mold Rubbers, Poly 74/75 Part X can be added to accelerate
the cure. Poly 74/75 Part X may accelerate other Polytek
polyurethane mold rubbers. Test on a small scale first.
• Thickeners - Poly Fiber II is a fine fiber that is used to thick- Molds and castings made from Polytek polyurethane products.
en polyurethane rubbers and plastics to a thixotropic consis-
tency for brushed rubber molds and plastic shells. Cab-O-
Sil® Fumed Silica is both a thickener and thixotropic agent.
ADDITIVES & ACCESSORIES
Add Poly Fiber II or Cab-O-Sil to mixed Parts A and B in Poly 74 Part C Softener
order to form a gel appropriate for application by brush or 1 pint (1 lb), 1 gal (8 lb), 5 gal (40 lb)
trowel. Cab-O-Sil is only appropriate for use with certain liquid
Poly 74/75 Part X Accelerator
mold rubber products.
1 pint (1 lb), 1 gal (8 lb)
• UV Stabilizer - Poly UV Additive can be added to mixed
Parts A and B to improve UV resistance of cured Polytek Pol-Ease® 2300 Release Agent
mold rubbers. At 0.5% of the total weight of the liquid mix, 12-oz. can, case of 12 cans
UV Additive reduces characteristic surface degradation Pol-Ease® 2450 Release Agent
caused by sunlight and other UV sources. 1 qt (2 lb), 5 gal (40 lb)
• Colors - Polyurethanes can be tinted to various colors by Pol-Ease® 2500 Release Agent
adding small amounts of PolyColors (see p. 61). 12-oz. can, case of 12 cans
To learn more about additives, refer to product technical bulletins Pol-Ease® 2601 Release Agent
or call Polytek Customer Service. Additives and accessories for 1 qt (2 lb), 5 gal (40 lb), Drum (450 lb)
polyurethane mold rubbers are listed in the box to the right.
Pol-Ease® 2650 Release Agent
CLEAN UP 1 qt (1.5 lb), 5 gal (35 lb), Drum (375 lb)
Tools should be wiped clean before the rubber cures. Denatured Pol-Ease® Mold Rinse or Mold Dressing
ethanol is a good cleaning solvent, but it must be handled with 5 gal (40 lb)
extreme caution owing to its flammability and health hazards.
Poly PVA Solution (Green or Clear)
Work surfaces can be waxed or coated with Pol-Ease 2300
1 qt (2 lb), 5 gal (40 lb)
Release Agent so cured rubber can be removed.
PolyCoat
SAFETY 1 qt (1.5 lb), 1 gal
Before use, read product labels and Material Safety Data Sheets. Poly Purge™ Aerosol Dry Gas
Follow safety precautions and directions. Contact with uncured 10-oz can, Case of 12 cans
products may cause eye, skin and/or respiratory irritation and der-
Cab-O-Sil®/Fumed Silica
mal and/or respiratory sensitization. Avoid contact with skin and 5 gal, 1 bag (10 lb)
eyes. If skin contact occurs, remove with waterless hand cleaner
Poly Fiber II
or alcohol then soap and water. In case of eye contact, flush with
5-gal pail (~3 lb), bag (10 lb)
water for 15 minutes and call a physician. Use only with adequate
ventilation. Do not use polyurethane products where food or body and, therefore, should be used up as soon as possible after opening.
contact may occur. Polyurethanes burn readily when ignited. After opening, spray Poly Purge™ Dry Gas Blanket into containers
STORAGE LIFE before resealing to displace moist air and extend storage life.
At least six months in unopened containers stored at room temper- Polyurethane rubber molds can last many years if stored in their
ature (60-90°F). Parts A and B react with atmospheric moisture proper shape in a cool, dry location out of direct sunlight.
33
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 2 Polyurethane RTV Mold Rubbers

Poly 74 and 75 Series RTV Liquid Rubbers

DESCRIPTION: Poly 74 and 75 Series Liquid Rubbers consist
of Part A and Part B that, after mixing, cure overnight at room FEATURES
temperature to flexible, high-strength, mold rubbers. Poly 74 and • Easy-to-use formulations
75 Series Rubbers make durable, easy releasing molds for casting • Flexible, strong mold rubbers
Polyurethane
Mold Rubber

plasters and waxes without release agents, but when used with
proper release agents are also excellent for casting concrete,
epoxy, polyester, urethane and acrylic.
MODEL PREPARATION: See p. 32.
MIXING AND CURING: See p. 32.
USING THE MOLD: See p. 32.
ADDITIVES: For general guidelines see p. 33.
Softener - For the Poly 74 and 75 Series RTV Liquid Mold
Rubbers, Poly 74/75 Part C Softener can be added to the uncured
products for a lower viscosity mix and a softer cured rubber.
When Part C is used, cure time is longer and there is some loss of
strength in the rubber and increased tendency to shrink after
repeated castings. To soften Poly 74-30 to a Shore A15, mix
1A:1B:1C, by weight. The quantity of Part C required to soften
other products varies and should be determined through experi-
mentation.
Accelerator - For the Poly 74 and 75 Series RTV Liquid Mold
Rubbers, Poly 74/75 Part X can be added to accelerate the cure.
Part X is most useful when making brush-on molds with 74-
Series rubbers to decrease the time needed between coats. By
adding 3% Part X (by weight of the total mix) to 74-30 or 74-29,
• Reproduce fine details
• Make tough, long-lasting molds and parts
the working time is reduced to approximately 8 minutes -- in the
time it takes to mix the next batch, the previous brushed layer
gels enough to apply the next coat. Demolding is possible in as
little as 4 hours after the final layer is applied. Rapid curing with
Part X allows a firm, yet flexible shell or mother mold to be made
in the same day. For example, by adding 1% Part X (by weight
of total mix) to Poly 75-80, the working time is reduced to
approximately 10 minutes and demolding is possible in as little
as 6 hours.
Exercise caution when using Part X for poured molds since the
rapid onset of gelling may trap air bubbles on or near the surface
of the master.
Poly 74/75 Part X affects each product differently. Before use,
testing to determine the best amount of Part X to use is advised.
CLEAN UP: See p. 33.
SAFETY: See p. 33.

POLY 74 SERIES PHYSICAL PROPERTIES

74-20 74-29 74-30 74-40 74-44 74-45 74-55
(74-29 White) (74-30 Clear)
Mix Ratio, By Weight 1A:2B 1A:1B 1A:1B 2A:1B 2A:1B 1A:1B 4A:1B
Hardness, Shore A 20 30 30 40 45 45 55
Pour Time (min) 30 30 30 20 20 30 15
Cured Color* Yellow Black Varies Varies Gray Yellow Clr Yellow
(White) (Clear/Amber)
Mixed Viscosity (cP) 800 2,800 2,000 3,400 3,500 2,500 4,000
Specific Volume (in /lb)
3
27.5 27.5 27.5 27.5 27.5 27.5 27.5

POLY 75 SERIES PHYSICAL PROPERTIES

75-59 75-60 75-65 75-70 75-75 75-79 75-80 75-90
Mix Ratio, By Weight 1A:1B 1A:1B 1A:1B 1A:1B 2A:1B 2A:1B 2A:1B 2A:1B
Hardness, Shore A 60 60 65 70 75 80 80 90
Pour Time (min) 10 10 35 40 20 20 45 10-15
Cured Color Amber Amber Yellow/Amber Gray Amber Yellow Yellow/Amber Tan/Brown
Mixed Viscosity (cP) 2,500 1,200 3,000 3000 4,000 2,000 5,000 6,000
Specific Volume, in /lb
3
27 27 27 27 26 26 26 26
* Some Part Bs darken with age, but cured rubber properties are not affected.

34
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 Polyurethane RTV Mold Rubbers 2
Poly 74-20 offers the most Poly 74-40 was used to make
remarkable combination of a poured blanket mold of this
tear strength and softness. shelf bracket. The bracket was
With tear strength similar to rotocast using Poly 15-3X
harder rubbers, Poly 74-20 polyurethane to make a hollow
pulls away from detail and part that was then backfilled
undercuts with no trouble at with Poly 15-6 and Part 15F
all. Poly 74-20 is great for Foamer to give it strength

Polyurethane
Mold Rubber
casting concrete, plaster while keeping it lightweight
wax and resins. and low cost.

Moldmaker Chan A satisfied seminar

Oeur (looking at attendee displays her
camera) demolds a cold cast bronze pot
Poly 74-30 brushed demolded from a two-
mold from one of six piece, poured block mold
panels created by made from Poly 74-20.
artist Kate Burke for The keys, which register
the Minnesota the top and bottom
Veteran’s Home. halves of the mold,
They sprayed the worked perfectly to cre-
model with Pol-Ease ® ate a thin, uniform wall
2300 Release Agent, thickness on the cast
so the separation part.
was perfectly clean
and trouble-free.

74- & 75-Series Packaging

Unit Components
Product Unit Weight
(Mix Ratio) (lb) Part A (lb) Part B (lb) Part A (volume) Part B (volume)

6 2.0 4.0 1 qt 2 x 1 qt
Poly 74-20 24 8.0 16.0 1 gal 2 x 1 gal
Mix Ratio: 1A:2B 120 40.0 80.0 5 gal 2 x 5 gal
1,350 450 900 55 gal 22 x 5 gal/2 x 55 gal

Poly 74-29, 74-30, 74-30 Clear, 74-45 4 2.0 2.0 1 qt 1 qt

16 8.0 8.0 1 gal 1 gal
Poly 75-59, 75-60, 75-70 80 40.0 40.0 5 gal 5 gal
Mix Ratio: 1A:1B 900 450 450 55 gal 55 gal/11 x 5 gal

6 4.0 2.0 2 x 1 qt 1 qt
Poly 74-40, 74-44 24 16.0 8.0 2 x 1 gal 1 gal
Poly 75-75, 75-79, 75-80, 75-90 120 80.0 40.0 2 x 5 gal 5 gal
Mix Ratio: 2A:1B 675 450 225 55 gal 6 x 5 gal
1,350 900 450 2 x 55 gal 55 gal
5 4.0 1.0 2 x 1 qt 1 pt
20 16.0 4.0 2 x 1 gal 2 x 1 qt
Poly 74-55
40 32.0 8.0 5 gal 1 gal
Mix Ratio: 4A:1B
100 80.0 20.0 2 x 5 gal 5 gal
562.5 450 112.5 55 gal 3 x 5 gal

35
www.polytek.com
 2 Polyurethane RTV Mold Rubbers
®
Polygel Brushable/Sprayable Mold Rubber
U.S. Patent # 5,128,433

USES: Polygel® Mold Rubbers are without equal for brushed or

sprayed blanket molds. Polygel Plastics produce strong, light- FEATURES
weight mold shells (see p. 46). Polygel products are ideal for • Easy -- 1:1 mix by weight or volume
Polyurethane
Mold Rubber

molds and shells built up with a brush or spatula on vertical or

overhead surfaces. Evaluate Polygel Mold Rubbers for casting
plaster, cement and waxes, as well as for limited casting with
polyester, epoxy and polyurethane resins. Sprayable Polygel
products are ideal for large surface area applications where brush-
ing may be impractical. Polygel products bond well to many sur-
faces and should be evaluated as adhesives and sealants.
DESCRIPTION: Polygel products consist of liquid Parts A and
B, that after mixing 1:1 by weight or volume, immediately self-
thicken to a brushable or trowellable consistency. As the liquid
components of Polygel Mold Rubbers are mixed together, the
product changes color and thickens to a buttery, non-sag paste
with a working time of 1 to 20 minutes (depending on the specif-
ic Polygel product used). A mold can be built up in 2 to 3 coats,
applied about 1 hour apart. Polygel Spray 35, Spray 50 and Quick
Spray 50 can be sprayed continuously until the desired mold
thickness is achieved. Polygel rubbers cure overnight at room
temperature to flexible, tough rubbers. Polygel Spray 35 and
Quick Spray 50 cure in 4-6 hours.
MODEL PREPARATION: See p. 32.
MIXING AND CURING: See p. 32.
Polygel Product Options
Polygel® 35 - Softest, most elastic, brushable Polygel rubber.
Cures to Shore A35 hardness in 4-6 hours.
Polygel® Spray 35 - Sprayable version of Polygel 35
designed for use with meter-mix spray equipment.
• Excellent for brush-on and spray applications
• Fast -- one-day molds
• Tough and strong
• Color-coded mix indication
• Molds have long library life
• Good flow into fine detail
• Good dimensional stability
BRUSH-ON MOLDS WITH POLYGEL RUBBER: When
brushing Polygel rubber, allow the first coat to gel enough so that
the second coat will not disturb it (usually about 1 hour is ade-
quate, 30 minutes for Polygel 35), then apply a second coat being
careful to cover any thin spots in the first coat. Do not allow prior
layers to cure completely before applying subsequent coats.
Sprayed molds should be made in one continuous application
without the need for individual layers. Ideally, a blanket mold
should be at least 1/8-inch thick but not more than 3/8-inch, since
too thick a layer of rubber causes difficulty turning a mold back
on itself during demolding. Allow to cure at room temperature
prior to demolding or building the mold shell. Strength continues
to develop for several days.
REINFORCING BRUSH-ON MOLDS: Rubber molds can be
reinforced with Tietex® Fabric (see Accessories), which is strong
and wets out better than other fabrics. Tietex can be laminated at
the top of a seam or strips can be laid around the perimeter of a
mold to prevent tearing. The fabric can be embedded in the sec-
ond or third coat of rubber while tacky and covered with a subse-
quent coat, which should be as fluid as possible for best penetra-

Polygel® 40 - The lowest viscosity mix for best air bubble

release and easiest brushing. Cures to a Shore A40 hardness.

Polygel® 50 - A thicker mix that cures to a tough Shore A50

hardness. Polygel 50 is a great adhesive for repairing
polyurethane molds and bonding molds to backing material
such as plywood.

Polygel® Spray 50 - Designed for spray mold applications

using meter-mix spray equipment.

Polygel® Quick Spray 50 - A fast, sprayable mold rubber

with a 1-minute working time and a 4 to 6-hour cure.

Polygel® Plastic-75 - See p. 55. Polygel ® Mold Rubbers are specifically designed for brush-on
and spray application. After Parts A+B are mixed, they form a
Polygel® Shell - See p. 55. thixotropic gel that clings to vertical and overhang surfaces after
application.

36
(610)559-8620 • (800)858-5990
 Polyurethane RTV Mold Rubbers 2
Polygel® Spray 50 is A large, flexible
applied to a monu- rubber dome
mental sculpture with mold was made
the VS-3000 Polygel quickly using
Sprayer (see p. 64). Polygel ® Spray
Using the sprayer, the 50 for the
entire mold was made restoration of
in a continuous the St. Joseph

Polyurethane
Mold Rubber
sprayed piece. The County
gel emitting from the Courthouse in
sprayer is non-sag Southbend, IN.
and, therefore, stays
where it is applied,
but can be moved
around with a brush if Using Polygel ®
necessary. Spray 50 a mold
was made of
this this large
cornice bracket.

tion of the cloth. If the fabric is too close to the model surface, the
weave pattern may show through to the face of the mold.
NOTE ON LAYERING DIFFERENT POLYGEL RUBBERS:
Typically, brush-on molds should be completed with one rubber.
For example, if the face coat is brushed with Polygel 40, then all
subsequent coats should be with Polygel 40. In some cases, the
initial coat can be brushed with lower viscosity Polygel 35 or 40
This Polygel ®
for better detail and the second (usually final) coat with thicker
mold was used
Polygel 50 to speed the mold making process. This technique is
to rotocast hol-
acceptable for molds that do not require long-term storage or use.
low plaster
When layering different products, oils can transfer from one rub-
columns used
ber to another causing warping or curling of the mold. In extreme
routinely for
cases, a mold can distort enough that it will not fit properly into
home and office
its shell.
decor.
THICKER MIXES FOR FILLING UNDERCUTS: Polygel
Mold Rubbers can be made even thicker by stirring Poly Fiber II
or Cab-O-Sil® into the mixed Parts A and B.
USING THE MOLD: See p. 32. If a Polygel rubber mold is to
be turned inside out like a sock, the outside surface must be lubri-
cated with soapy water or petroleum jelly so that it slides over
itself easily. The shell or mother mold can be made of Polygel
Plastics, plaster, polyester resin and fiberglass, or Poly 15-6 or
1512X resin filled with Poly Fiber or fiberglass (see p. 61). If the
shell is built with Polygel Plastics or other resin, the rubber must
be thoroughly coated with paste wax then Pol-Ease 2300 Release POLYGEL MOLD RUBBER PACKAGING
Agent to prevent the plastic from sticking to the rubber. A plaster
shell must be sealed with potter’s soap, shellac, lacquer or wax to Products Unit Weight (A+B)
prevent mold distortion during storage or use. 4 lb
Polygel 35
CLEAN UP: See p. 33. 16 lb
Polygel 40
80 lb
SAFETY: See p. 33. When spraying Polygel products, use ade- Polygel 50
900 lb
quate ventilation and personal protective equipment (i.e., respira-
tors, gloves, coveralls). Polygel Spray 35
80 lb
Polygel Spray 50
900 lb
Polygel Quick Spray 50

37
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 2 Polyurethane RTV Mold Rubbers

Poly 77 Series RTV Liquid Rubbers

DESCRIPTION: Poly 77 Series RTV Liquid Rubbers consist of
a liquid Part A and Part B that, after mixing, cure at room tem- FEATURES
perature to economical, flexible mold rubbers. Consider these • High-performance, high-elongation rubbers
products for casting plasters, cements and waxes. Resins can also
be cast with proper release agents. The Poly 77 Series has been • Hardnesses ranging from Shore A50 to A65
Polyurethane
Mold Rubber

formulated to provide excellent abrasion and tear resistance for • Easy-to-use formulations with 1:1 mix ratios
maximum mold life and performance. The high elongation char- • Easy demolding without damaging molds
acteristic of these rubbers enables easier demolding and reduces
• Make tough, long-lasting molds
mold damage when used in demanding casting applications.
MODEL PREPARATION: See p. 32.
MIXING AND CURING: See p. 32. PACKAGING
USING THE MOLD: See p. 32. Poly 77-50 and Poly 77-65
CLEAN UP & SAFETY: See p. 33. Mix Ratio: 1A:1B (By Weight)

PHYSICAL PROPERTIES Unit Weight Unit Components

(lb)
77-50 77-65 Part A Part B Part A Part B
Mix Ratio, By Weight 1A:1B 1A:1B (lb) (lb) (Volume) (Volume)
Hardness, Shore A 50 65
Pour Time(min) 15 15 4.0 2.0 2.0 1 qt 1 qt
Color Tan Tan 16.0 8.0 8.0 1 gal 1 gal
Mixed Viscosity (cP) 1,200 1,600 80.0 40.0 40.0 5 gal 5 gal
900 450 450 55 gal 55 gal
Specific Volume (in3/lb) 27.5 27.5

Poly 81 Series RTV Liquid Rubbers

DESCRIPTION: Use Poly 81 Series rubbers to make firm
molds, mold facings, stamping tools, industrial parts, rollers, gas- FEATURES
kets, mold shells, bumpers or pads. Poly 81 Series rubbers con-
• Firm rubbers ranging from Shore A90 to D45
sist of liquid Part A and Part B that, after mixing, cure at room
temperature to tough, durable rubbers. They offer low sensitivity • Easy-to-use formulations
to moisture, and low viscosity for easy vacuuming, if necessary. • Reproduce fine details
MODEL PREPARATION: See p. 32. • Make tough, long-lasting molds, tools and parts
MIXING AND CURING: See p. 32. Parts A and B are clear liq-
uids. The color of Part B may vary, but it has no effect on cured
rubber properties.
PACKAGING
USING THE MOLD: See p. 32.
Poly 81-Series
CLEAN UP & SAFETY: See p. 33.
Component Weight (lb)
PHYSICAL PROPERTIES Product Unit
(Mix Ratio) Weight (lb)
81-90 81-D45 Part A Part B
Mix Ratio, By Weight 100A:40B 100A:20B 11.2 8.0 3.2
Hardness (Shore A/D) A90 D45 Poly 81-90 56.0 40.0 16.0
Pour Time (min) 23 19 (100A:40B) 280 200 80.0
Demold Time (hr) 16 16 630 450 180
Color Yellow Varies 9.6 8.0 1.6
Mixed Viscosity (cP) 2,000 1,600 Poly 81-D45 48.0 40.0 8.0
(100A:20B) 192 160 32.0
Specific Volume (in3/lb) 26.6 26.4 540 450 90.0

38
(610)559-8620 • (800)858-5990
 Polyurethane RTV Mold Rubbers 2
Poly 72-40 Series RTV Liquid Rubbers
DESCRIPTION: Poly 72-40 systems consist of liquid Part A and
Part B that, after mixing in correct ratio, cure at room temperature PHYSICAL PROPERTIES
to versatile mold rubbers. They may be poured or thickened and Mix Ratio, By Weight 1A:10B
applied by trowel or brush, to make flexible molds. These molds Hardness, Shore A 40
are typically used for making wax castings in foundry applications. Pour Time (min) 30

Polyurethane
Mold Rubber
MODEL PREPARATION: See p. 32. CAUTION: Poly 72-40 Cured Color Ivory
systems may be subject to cure inhibition by certain contaminants Mixed Viscosity (cP) 4,000
and may stick to some surfaces. See Technical Bulletin for details.
Specific Volume (in3/lb) 20
MIXING AND CURING: See p. 32. See Technical Bulletin for Shrinkage Upon Cure Nil
details regarding mixing, curing and use of additives to thicken for
brush-on application (e.g., fumed silica, Poly Fiber II, and Part D).
USING THE MOLD: See p. 32 and Technical Bulletin. PACKAGING
SOFTER MOLDS: Add Part C Softener to Part B before mixing Poly-Fast 72-40 and Poly 72-40 MF
with Part A. Consult Technical Bulletin for details. Mix Ratio 1A:10B (By Weight)
STORAGE: Poly 72-40 rubber remains usable for at least 6
months from the date of shipment in unopened containers, stored in Unit Weight Unit Components
(lb)
a cool, dry location. Cured molds slowly soften with age. Adequate
mixing of components in the proper mix ratio contributes to long Part A Part B Part A Part B
mold life as will storage of molds in a dark, cool, dry area. With (lb) (lb) (Volume) (Volume)

proper care, Poly 72-40 molds should not soften appreciably for 2-
9.9 0.9 9.0 1 pt 1 gal
4 years. Molds should be discarded before they become too soft to 49.5 4.5 45.0 ½ gal 5 gal
handle. Do not store molds outdoors, as exposure to sunlight and 495 45.0 450 5 gal 55 gal
excessive humidity will cause rapid deterioration of the rubber.

Poly GlassRub Liquid Rubber

Poly GlassRub 50 RTV Liquid Rubber consists of two parts (A &
B) that, after mixing, cure at room temperature to a flexible, clear FEATURES
rubber. Poly GlassRub 50 is designed for making clear molds that
can be easily cut away from original objects with less chance of • Glass-like appearance (clear, pale blue)
damage and better seam positioning since objects are visible • Reproduces fine detail
through the rubber. Additionally, clear rubber castings or objects • Easy-to-use formulation -- 1A to 1B mix ratio
encapsulated in the clear rubber can make interesting original art
• Low viscosity mix with excellent bubble-release
or displays. Cured GlassRub may yellow slightly over time or fol-
lowing UV exposure. PolyColors can be added to the liquid rubber • Long working time
to make a tinted or colored, yet still clear, rubber. The smallest addi-
tion of a PolyColor virtually eliminates post-cure yellowing.
For more information, consult the GlassRub Technical Bulletin.
GlassRub 50 Liquid Rubber Packaging
1A:1B Mix Ratio
PHYSICAL PROPERTIES
Mix Ratio, By Weight or Volume 1A:1B Weight Volume
Hardness, Shore A 45-50 Unit Weight
Pour Time, 1-lb mix (min) 45 A (lb) B (lb) A B
Demold Time (hr) 16
Specific Gravity 1.0
4 lb 2 2 1 qt 1 qt
Color, Cured Glass Like/Blue-Clear*
16 lb 8 8 1 gal 1 gal
Viscosity, 2.5 min after mix (cP) 1000
Specific Volume(in3/lb) 27.5
80 lb 40 40 5 gal 5 gal
* Upon exposure to UV light (i.e., fluorescent light or sunlight), cured
rubber may yellow with age. 900 lb 450 450 55 gal 55 gal

39
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 3 Silicone RTV Mold Rubbers
®
Poly-Sil Silicone RTV Liquid Mold Rubbers
The Poly-Sil® Silicone RTV Liquid Mold Rubbers each consist
of a Part A and Part B, which, after mixing, cure at room
temperature to flexible, high-strength, mold rubbers. Poly-Sil
Mold Rubbers make molds that are easy releasing and stable at
higher temperatures. They are excellent for casting plasters,
waxes, cements, low melting metals and many resins such as
epoxies, polyesters, urethanes and acrylics.
As with other Polytek elastomers, the last two digits in the
product name indicate the approximate Shore A hardness of the
cured rubber. Poly-Sil rubbers range in hardness from a very soft
A10 to a firm A60.
Mold Rubber
MODEL PREPARATION
Silicone
Porous models such as wood or plaster should be sealed to
prevent penetration of the rubber into the pores of the material.
Wax, petroleum jelly, lacquer, paint and most other coatings are
suitable sealers. Materials that will contact the rubber can be
sprayed or coated with a light coat of Pol-Ease® 2350, which
functions as a sealer and release agent. Allow the Pol-Ease 2350
to dry before applying liquid rubber. Silicone-based release
agents (i.e., Pol-Ease® 2300) are not to be used on surfaces that
contact liquid Poly-Sil® rubbers since inhibition and/or adhesion
may occur. In addition, modeling clays containing sulfur may
inhibit curing. In every case where there is any question about
the compatibility between the rubber and the prepared model
surface, a test cure should be made on an identical surface to
determine that complete curing and good release are obtained.
Poly-Sil rubbers may bond to cured silicone rubbers unless a
parting agent is used.
Porous models must be vented from beneath to prevent trapped
air from forming bubbles in the rubber (see p. 12).
MIXING AND CURING
Before mixing rubber, be sure that both Parts A and B are at
room temperature and that all tools and models are ready to go!
Check product labels or technical bulletins to determine working
time for the product -- some products set fast -- meaning that
you must work quickly.
Many Poly-Sil Part As require stirring before use. If there is a
“Stir Before Use” label on the container -- be sure to do so.
Molds made from high-
performance Poly-Sil ®
rubbers are best for casting
harsh resins. This gargoyle
blanket mold made of soft
PlatSil ® 71-11 easily pulls
off the cast resin part. The
smooth, release-free
demold of silicone is
especially welcome on
highly detailed parts.
40
POLY-SIL® MOLD RUBBERS: AT A GLANCE
TinSil® 70 Series - Tin-catalyzed silicone systems that
cure to tough, high-performance rubbers with easy
release properties and resistance to high temperatures.
Great for casting polyester resin.
PlatSil® 71 Series - High-tear strength, platinum-cured
silicone systems with hardness up to A40. Excellent for
casting polyurethane resins and dimensionally accurate
prototype parts.
PlatSil® 73 Series - High-tear strength, tough, platinum-
cured silicone systems with hardness up to A60.
Excellent for casting polyurethane foams and
dimensionally accurate prototype parts.
PlatSil® Gel 10 - A soft, translucent rubber for delicate
casting projects and special effects applications.
Mix Ratios Vary! Check the mix ratios for the specific product
you are using. For Poly-Sil rubbers, most mix ratios are
expressed by weight. Carefully weigh Parts A and B in proper
ratio. Accurate weighing is essential to obtain optimum physical
properties from the cured rubber. Weigh Part B into a clean
metal or plastic mixing container. Then weigh the appropriate
amount of Part A into the same container. Mix thoroughly,
scraping sides and bottom of the container. Hand mixing with a
Poly Paddle (see p. 62) is best to avoid mixing air into the rubber.
To ensure a bubble-free mold, deaerate the liquid rubber under
vacuum at 28-29 inches mercury until the mass of rubber rises
and then collapses. Deaerate for an additional 2 minutes. For
vacuuming, use a mixing container 3 to 4 times larger than the
volume of rubber. Pour the rubber as soon after mixing as possible
for best flow and air bubble release.
If reinforcement of the rubber is needed (i.e., in thin blanket
molds), place stretchy, open mesh nylon or dacron cloth into the
uncured rubber. Be sure that the fabric is not too close to the
mold surface or the weave of the cloth may show through to the
face of the mold.
Check product labels or technical bulletins to determine cure
times. To reach full hardness in the specified demold time,
temperature should be above 77°F (25°C). At lower temperatures,
more time may be needed to reach full hardness. Curing below
65°F (18°C) is not recommended. For most Poly-Sil products,
final cure properties are obtained in about seven days, but most
molds may be used with care after curing for 24 to 48 hours.
USING THE MOLD
No release agent is necessary for casting most materials in Poly-
Sil molds. For longer mold life, however, a barrier coat or release
agent (i.e., Pol-Ease® 2300) is recommended when casting epoxy,
(610)559-8620 • (800)858-5990
 Silicone RTV Mold Rubbers 3
polyurethane or polyester resins. Most Poly-Sil molds can be
stored for years, but tin-catalyzed silicone molds eventually TINSIL & PLATSIL ACCESSORIES
deteriorate and lose their elasticity.
Pol-Ease® 2300 Release Agent
ADDITIVES & ACCESSORIES 12-oz can, case of 12 cans
Polytek offers various additives that can be used to vary the
Pol-Ease® 2350 Release Agent
properties of the cured and uncured Poly-Sil rubbers.
1 qt (1.5 lb), 5 gal (26 lb)
Š Thinner/Softener - Very low viscosity 50 cSt Silicone Fluid
Pol-Ease® 2500 Release Agent
can be added sparingly to the mixed rubber to thin the mix
12-oz can, case of 12 cans
with some loss of strength, hardness and cure speed. More
than 10% fluid addition may exude from the cured rubber. Silicone Fluid 50 cSt Grade
Š Accelerator - A specially formulated accelerator can be For Thinning Poly-Sil® Rubbers
added to most Poly-Sil products to reduce the cure time. 1 qt (2 lb), 1 gal (8 lb), 5 gal (40 lb)
Š Thickener - Specially formulated chemical thickeners can TinSil® FastCat
be added to most Poly-Sil products to make the liquid 4 oz, 1 pt (1 lb), 1 gal (8 lb)
rubber thicker (i.e., for brush-on application). Cab-O-Sil® TinThix

Mold Rubber
Fumed Silica, which is both a thickener and thixotropic 4 oz, 1 pt (1 lb)

Silicone
agent, can also be added to mixed Parts A and B in order to PlatSil® 71/73X Accelerator
form a gel appropriate for application by brush or trowel. 4 oz, 1 pt (1 lb), 1 gal (8 lb)
Š Colors - Certain Poly-Sil rubbers can be tinted to various
PlatSil® 71R Retarder
shades by adding small amounts of colors.
4 oz, 1 pt (1 lb), 1 gal (8 lb), 5 gal (40 lb)
Š Barrier Coat - A barrier coat (i.e., Barrier PF) is a fast
PlatThix
drying, lacquer-like primer that is sprayed into a silicone
4 oz, 1 pt (1 lb)
mold and allowed to dry prior to pouring plastic. The
plastic cures against the barrier coat and comes out on the Barrier PF
plastic casting resulting in a pre-primed part. Using a 1 qt (1.5 lb), 5 gal (35 lb)
barrier coat may extend mold life. Cab-O-Sil®/Fumed Silica
To learn more about additives, refer to product technical 5 gal, 1 bag (10 lb)
bulletins or call Polytek Customer Service. See additives and Smith’s Theatrical Prosthetic Deadener
accessories for Poly-Sil products in the box to the right. 1 qt (2 lb), 1 gal (8 lb), 5 gal (40 lb)
CLEAN UP
Tools should be wiped clean before the rubber cures. Denatured
ethanol is a good cleaning solvent, but it must be handled with
extreme caution owing to its flammability and health hazards.
SAFETY
Before use, read product labels and Material Safety Data Sheets.
Follow safety precautions and directions. Contact with uncured
products may cause eye, skin and/or respiratory irritation. Avoid
contact with skin and eyes. If skin contact occurs, remove with
waterless hand cleaner or alcohol then soap and water. In case of
eye contact, flush with water for 15 minutes and call a
physician. Use only with adequate ventilation. Poly-Sil products
are not to be used where food or body contact may occur.
STORAGE LIFE
At least six months in unopened containers stored at room
temperature (60-90°F).

CAUTION! -- Certain chemicals cause cure

inhibition in silicone rubbers. Beware of amines,
polyesters and tin compounds with PlatSil
systems. Sulfur compounds can affect both
PlatSil and TinSil systems. Perform a test cure!
Poly-Sil ® rubber blanket molds reproduce the fine details of models
and are soft and tough enough to easily pull off complex castings.
Usually, the more intricate the model/casting, the softer the mold
rubber selected. This very ornate column capital was easily cast
in TinSil ® 70-11. The gargoyle mold was made using PlatSil ® 71-
20. The large, multi-piece, Ronald McDonald ® mold was made
using TinSil ® 70-30 to cast numerous polyester resin parts.

41
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 3 Silicone RTV Mold Rubbers
®
TinSil 70 Series
DESCRIPTION: TinSil® 70 Series RTV Silicone Rubbers are
condensation-cure, tin-catalyzed, flexible mold rubbers. TinSil
products consist of a liquid Part B base and Part A accelerator,
which, after mixing at the proper ratio by weight, cure at room
temperature to rubber with a tough, knotty tear property. TinSil
molds have easy release properties and are resistant to high
temperatures. TinSil molds are excellent for casting polyesters,
epoxy and polyurethane resins; waxes and many other materials.
Choose the appropriate hardness of rubber for your application.
• TinSil 70-11, 70-20 and Gel-10 are soft and, therefore, best
for delicate castings. Gel-10 is translucent and especially
useful for animatronics and special effects.
Mold Rubber
MODEL PREPARATION: See p. 40.
MIXING AND CURING: See p. 40. CAUTION! TinSil products
release alcohol while curing, which results in slight shrinkage of
the rubber (up to 1%) and can inhibit the surface cure of some
polyurethanes. If shrinkage cannot be tolerated, consider PlatSil
rubbers. Before casting polyurethanes in a TinSil mold, evaporate
alcohol by letting the mold sit in a warm location for 24 hours or
by baking the mold for 4 hours at ~200°F.
USING THE MOLD: See p. 40. [Note: Molds made with excess
catalyst may be subject to faster degradation on aging.]
ACCELERATING CURE SPEED: Use TinSil FastCat in place
of any TinSil Part A in order to accelerate cure and shorten

• TinSil 70-25 and 70-30 are Polytek’s most popular and demold time. FastCat can be used in a range of 2-6 parts per 100
Silicone

versatile, mid-range hardness, silicone rubbers.
• TinSil Spray-25 is sprayable or brushable and can be
applied by hand or sprayed with a low-cost Plas-Pak spray
gun or more sophisicated 1A:10B silicone spray equipment.
Spray 25 is great for large scale blanket molds!
• TinSil 70-39 is firm with excellent tear properties making it
popular for casting polyurethane foams and plastic prototypes.
• TinSil 70-60 is stable at higher temperatures making it
suitable for casting low melting metals. TinSil 70-60 has
limited tear strength because of its hardness.
parts B; see product technical bulletin for details. Use of FastCat
can shorten the library life of cured TinSil rubber.
THICKENING FOR BRUSH ON: Add TinThix liquid
thickener or Cab-O-Sil® to liquid TinSil rubbers for brushing on
a blanket mold. TinThix can be mixed into the Part B (before
mixing with Part A) to achieve varying levels of thixotropy.
ACCESSORIES: See box on p. 41.
SAFETY: See p. 41.

TinSil Physical Properties

70-11 & Gel-10 70-20 70-25 Spray-25 70-30 70-39 70-60
Mix Ratio (By Weight) 1A:10B 1A:10B 1A:10B 1A:10B 2A:100B 1A:10B 5A:100B
Hardness, Shore A 10 20 25 25 30 40 60
Pour Time (min) 45 60 60 30 60 45 30
Demold Time @ 77°F (hr) 16 16 16 16-24 24 16 24
Color Blue (70-11) Blue Blue Translucent Beige Blue Red
Transluscent (Gel-10)
Mixed Viscosity (cP) 10,000 10,000 14,000 Thixotropic 26,000 25,000 17,000
Specific Volume (in /lb)
3 25.3 25.3 25.3 25.3 25.3 21.7 18
Specific Gravity 1.1 1.1 1.1 1.1 1.1 1.27 1.5
Shrinkage Upon Cure (%) ~0.3 ~0.3 ~0.3 ~0.3 ~0.3 ~0.3 ~0.8

TinSil Packaging
TinSil Product
Unit Sizes (lb) Part A (lb) Part B (lb)
1.0 0.1 0.9
Gel-10, 70-11, 70-20, 70-25, Spray 2.0 (Spray 25 Cartridge) 0.2 1.8
25 and 70-39 9.0 0.9 8.1
Mix Ratio 1A:10B 44.0 4.0 40.0
495 45.0 450
1.02 0.02 1.0
70-30 8.3 0.2 8.1
Mix Ratio 2A:100B 40.8 0.8 40.0
448.8 8.8 440
1.05 0.05 1.0
70-60
8.4 0.4 8.0
Mix Ratio 5A:100B
42.0 2.0 40.0

42
(610)559-8620 • (800)858-5990
 Silicone RTV Mold Rubbers 3
®
PlatSil 71 Series
DESCRIPTION: PlatSil® 71 Series RTV Silicone Rubbers are
two-component, addition-cure, platinum-catalyzed, flexible mold
FEATURES
compounds. The 71 Series products exhibit a tough, knotty tear, • Easy mix ratios; some 1:1 mixes available
making them especially valuable to the mold making industry. • Cure at room temperature or accelerate with heat
They are excellent mold materials for casting polyester, epoxy
and polyurethane resins, as well as for waxes and many other • Easy release properties -- save on release agents
materials. PlatSil 71 Series products offer advantages over tin- • High tear strength -- fewer prematurely torn molds
catalyzed systems in certain applications because on curing they • Good chemical resistance for longer mold life
don’t shrink and don’t produce alcohol (like tin-catalyzed
silicones), which can inhibit polyurethane castings. • Low/zero shrinkage for dimensional reproduction
MODEL PREPARATION: See p. 40. • Range of hardnesses from A10 to A40
MIXING & CURING: See p. 40.
RETARDING CURE SPEED: PlatSil 71R added to PlatSil

Mold Rubber
USING THE MOLD: See p. 40. Part A prior to mixing with Part B slows the cure yielding longer

ACCELERATING CURE SPEED: Accelerate the cure with heat
or the addition of PlatSil 71/73X. Mix 71/73X with Part B prior
to adding Part A. Weigh and add Part A to the accelerated Part B
mixture and mix thoroughly. Pour over a properly prepared
model as soon after mixing as possible. The addition of 1 part
71/73X per 100 parts of Part B decreases the gel time to ~1/3 the
normal gel time. The addition of 2 parts decreases the normal gel
time to ~1/4. The addition of 3 parts decreases the normal gel
time to ~1/6. Experimentation on a small scale is recommended
before making a larger mix.
Silicone
working time and longer demold time. Adding ~1% of 71R to
the total mixed weight of PlatSil A+B roughly doubles the
working time. Adding ~2% of 71R triples working time. Do not
use more than 4% as the system may not cure at all.
THICKENING FOR BRUSH ON: For brushing on skin mold,
thicken PlatSil 71 Series rubbers with PlatThix or Cab-O-Sil.
When brushing PlatSil 71-11 or 71-20, apply subsequent coats to
the previous layer within one hour to obtain best adhesion.
ACCESSORIES: See box on p. 41.
SAFETY: See p. 41.

PHYSICAL PROPERTIES
71-10 71-11 71-20 71-30 71-35 71-40
Mix Ratio (By Weight) 1A:10B 1A:1B 1A:1B 1A:10B 1A:10B 1A:5B
Hardness, Shore A 10 10 20 30 35 40
Pour Time (min) 5 20 25 60 60 60
Demold Time (hr) @ 77°F 0.5 4 4 24 24 24
Color Pink Blue Green Lt. Purple Lt.Green Blue Hazy transparent
Mixed Viscosity (cP) 3,500 6,000 12,000 25,000 25,000 25,000
Specific Volume (in3/lb) 26 24.7 24.7 24.7 24.7 25
Specific Gravity 1.06 1.12 1.12 1.12 1.12 1.10
Shrinkage Upon Cure Nil Nil Nil Nil Nil Nil

PACKAGING
Product Unit Weight Size Net Weight (lb)
(lb) A B A B
PlatSil® 71-11, 71-20 2.0 1 pt 1 pt 1.0 1.0
Mix Ratio 1A:1B 16.0 1 gal 1 gal 8.0 8.0
80 5 gal 5 gal 40.0 40.0
PlatSil® 71-10, 71-30, 71-35 1.0 4 oz 1 pt 0.1 0.9
Mix Ratio 1A:10B 9.0 1 pt 1 gal 0.9 8.1
44.0 ½ gal 5 gal 4.0 40.0
495 6 gal 55 gal 45.0 450
PlatSil® 71-40 9.8 1 qt 1 gal 1.7 8.1
Mix Ratio 1A:5B 48.0 1 gal 5 gal 8.0 40
528 2 x 6 gal 55 gal 88 440

43
www.polytek.com
 3 Silicone RTV Mold Rubbers
®
PlatSil 73 Series
DESCRIPTION: PlatSil® 73 Series RTV Silicone Rubbers are
two-component, high-tear strength, flexible mold compounds.
FEATURES
The 73 Series rubbers are excellent mold materials for many • Low viscosity for excellent detail reproduction and
casting materials including polyester, epoxy and polyurethane easy degassing.
resins. PlatSil 73 Series silicones are addition-cure, platinum- • Easy 10A:100B mix ratio -- can use with
catalyzed systems and offer advantages over tin-catalyzed dispensing machines
systems in certain applications because on curing they don’t
• Cure at room temperature or accelerate with heat
shrink, they don’t produce alcohol, which can inhibit urethane
castings, and their cure can be heat accelerated. • Easy release properties -- save on release agents
MODEL PREPARATION: See p. 40. • High tear strength -- fewer prematurely torn molds
MIXING & CURING: See p. 40. • Good chemical resistance for longer mold life
USING THE MOLD: See p. 40. • Low/zero shrinkage for better dimensional
Mold Rubber

reproduction
ACCELERATING CURE SPEED: Accelerate the cure with
Silicone

heat or the addition of PlatSil 71/73X. Weigh and add 71/73X to
Part B and mix. Weigh and add Part A to the accelerated Part B
mixture and mix thoroughly. Pour over a properly prepared
model as soon after mixing as possible. Demold when tack free.
The addition of 1 part 71/73X per 100 parts of Part B decreases
the gel time to ~35 min. The addition of 2 parts decreases the gel
time to ~30 min. The addition of 3 parts decreases the gel time to
~25 min. The addition of 71/73X softens the cured rubber
slightly. Remember, heat accelerates the cure; low temperatures
slow the cure.
• Range of hardnesses from A30 to A60
THICKENING FOR BRUSH ON: PlatSil 73 Series rubbers can
be thickened with PlatThix liquid thickener or with Cab-O-Sil®
for brushing on a blanket mold.
ACCESSORIES: See box on p. 41.
SAFETY: See p. 41.

PHYSICAL PROPERTIES
73-29 73-45 73-60
Mix Ratio, By Weight 10A:100B 10A:100B 10A:100B
Hardness, Shore A 30 45 60
Pour Time (min) 45 60 45
Demold Time @ 77oF (hr) 16 16 16
Color White Green Blue
Mixed Viscosity (cP) 15,000 35,000 40,000
Specific Volume (in3/lb) 25.0 21.3 21.3
Specific Gravity 1.10 1.30 1.30
Shrinkage Upon Cure Nil Nil Nil

PACKAGING
PlatSil® 73-29, 73-45, 73-60
Mix Ratio 10A:100B
Unit Weight Components
(lb) Size Net Weight (lb)
A B A B
1.0 4 oz 1 pt 0.1 0.9
9.0 1 pt 1 gal 0.9 8.1
44.0 0.5 gal 5 gal 4.0 40.0
495 (73-29) 6 gal 55 gal 45.0 450
550 6 gal 55 gal 50.0 500

44
(610)559-8620 • (800)858-5990
 Silicone RTV Mold Rubbers 3
®
PlatSil Gel-10
DESCRIPTION: Platil® Gel-10, a translucent, soft rubber, is an
excellent mold material for delicate casting projects and creating FEATURES
special effects. Gel-10 is a two-part, addition cure, liquid silicone • Soft (~A10), translucent, silicone rubber
system with an easy 1:1 mix ratio. After mixing Parts A and B, • Easy 1:1 mix ratio
Gel-10 cures within 30 minutes at room temperature to a soft,
• Fast 30-minute demold with 6-minute work time
tough rubber. Gel-10 does not shrink on curing.
• PlatSil® 71R Retarder slows the cure
For special effects, soften PlatSil Gel-10 by adding Smith’s
Theatrical Prosthetic Deadener. “Deadened” PlatSil Gel-10 is • PlatSil® 71/73X Accelerator speeds the cure
excellent for creating skins and self-sticking appliances. • PlatThix thickens the mix to a brushable paste
MODEL PREPARATION: See p. 40. • Bonds to Poly Plastics
MIXING AND CURING: See p. 40. Normal mixes gel in
approximately 6 minutes at room temperature; faster if warm, PlatSil Gel-10, the underlying gel can mimic the slow stretch and

Mold Rubber
slower if cold. Immediately place the mix over the model or in recovery properties of human tissue. Pigments can be added to

Silicone
the mold. There is not normally adequate time for vacuum PlatSil Gel-10 and/or Deadener to achieve any color needed.
(unless retarder is used), but pressure casting may be useful to
The term “deadener” was coined by Gordon Smith of FXSmith, who
eliminate bubbles.
developed this additive. Deadened Gel-10 does not have the springy,
Contamination with soaps, amines, sulfur, tin compounds and snappy feel typical of silicone rubber, but rather resembles the feel of
some RTV Silicone Rubbers may inhibit surface cure. human tissue. Go to www.fxsmith.com for more information.
USING THE MOLD: For best results, allow PlatSil Gel-10 to BONDING TO PLASTICS: PlatSil Gel-10 bonds to clean,
cure for at least 1 hour before use. No release agent is necessary cured Poly 15 Series plastics that are less than 24-hours old. See
for casting most materials in properly cured PlatSil Gel-10. For product technical bulletin for details.
longer mold life, however, use a barrier coat or release agent
ACCESSORIES: See box on p. 41.
when casting epoxy, polyurethane or polyester resins.
SAFETY: See p. 41.
ACCELERATING CURE SPEED:Mix PlatSil 71/73X into
Part B prior to adding Part A to accelerate gel time and cure. See
product technical bulletin for details. David Gavin and
RETARDING CURE SPEED: Add PlatSil 71R to Part A prior colleagues from Arran
to mixing with Part B to slow the cure for longer working time Studios in Cork, Ireland,
and demold time. Add 71R at 1% of the weight of total mix proudly display their
(A+B) to double the working time. Add up to 5% for a 60- Velociraptor casting made
minute work time with 120-minute demold time. with life-like PlatSil ® Gel-10
skin.
THICKENING FOR BRUSH ON: Thicken with TinThix liquid
thickener or with Cab-O-Sil® for brush-on application. Add 1%
TinThix to the total mix weight for a light-bodied, non-sag gel. PlatSil ® Gel-10 makes
great animatronic skins.
SMITH’S THEATRICAL PROSTHETIC DEADENER: Add
The product can be
up to 250% of Smith’s Deadener to the total Gel-10 mix weight
softened with the addition
(A+B) to create super soft, gel-like, self-sticking prosthetics or
of Silicone Fluid and
gel-filled appliances. If applied behind a casting of straight colored to make the look
and feel just right.
PHYSICAL PROPERTIES
Mix ratio, by weight 1A:1B
PACKAGING
Hardness, Shore A 10 + 2 Mix Ratio: 1A:1B (By Volume)
Pour time, minimum 6 min
Unit Weight Containers
Demold time @ 25°C (77°F) 30 min
(lb) Size Net Weight (lb)
Color Colorless
A B A B
Viscosity, mixed 15,000 cP
Specific volume (in3/lb) 25 2.0 1 pt 1 pt 1.0 1.0
Specific gravity @ 25°C (77°F) 1.10 16.0 1 gal 1 gal 8.0 8.0
Shrinkage upon cure Nil 80.0 5 gal 5 gal 40.0 40.0

45
www.polytek.com
 4 Casting Plastics/Resins
Casting & Mold Shell Plastics
Polytek liquid plastics are two-part systems that can be used to
cast decorative objects, parts, tools, and patterns as well as to cre-
ate lightweight mold shells to support brushed or sprayed blanket
molds. Polytek plastics can mimic materials of nearly any densi-
ty and appearance including lightweight foams, thermoplastics,
glass, wood, stone and metals. The products can be poured, layed
up or sprayed to accommodate any size casting or object. Varying
viscosities, pot-lives, cure times and physical properties allow the
user to choose a plastic tailored to their particular needs. The ver-
satility of Polytek Plastics is unlimited.
MOLD PREPARATION
Before pouring or applying liquid casting plastics, be sure that the
surface is properly prepared in order to prevent the plastic from
sticking or foaming. Polyethylene and silicone rubber molds, such
as TinSil® and PlatSil® products, do not require a release agent, but
a barrier coat may be helpful. Latex, polyurethane rubber or metal
molds must be dry and require a coat of Pol-Ease® 2300 Release
Agent. A trial casting or application should be made to avoid dam-
aging a valuable mold and/or wasting liquid plastic.
Casting Plastics
When using Poly Plastics to create lightweight mold shells, pre-
pare the rubber mold surface as described on p. 20. Poly 15-6,
1511 and Poly 1512X can be mixed with Poly Fiber to thicken the
pourable plastics to a thixotropic consistency that can be applied
to vertical and horizontal surfaces like frosting a cake. This
process is described in more detail on p. 22.
MIXING
Before mixing resins, be sure that both Parts A and B are at room
temperature and that all tools and molds are ready to go! Use
metal or plastic mixing vessels (i.e., polyethylene pail) and spat-
ulas to avoid introducing moisture. Check product labels or tech-
nical bulletins to determine working time for the product -- some
products set fast -- meaning that you must work quickly. Some
Polytek plastics require stirring before use. If there is a “Stir
Before Use” label on the container -- be sure to do so.
Mix Ratios Vary! Check the mix ratios for the specific product
you are using. Carefully weigh/measure Parts A and B in prop-
er ratio. Accurate weighing/measuring is essential to obtain opti-
mum physical properties from the cured plastic. Weigh/measure
Part B into a clean metal or plastic mixing container. Then
weigh/measure the appropriate amount of Part A into the same
container. Mix thoroughly, scraping sides and bottom of the con-
tainer. Hand mixing with a Poly Paddle (see p. 62) is best to avoid
mixing air into the plastic. Pour mix into mold cavity or apply to
surface as soon after mixing as possible.
Once the containers of Parts A and B are opened, they should be
used completely or resealed tightly as atmospheric moisture can
react with the Part A or may cause foaming of the plastic. Poly
Purge™, a dry gas product, can be sprayed into opened containers
of liquid plastics to lengthen shelf life once opened.
46
POLYTEK PLASTICS: AT A GLANCE
EasyFlo™ Series - Low viscosity, 1:1 mix by volume,
fast-setting plastics. Polytek’s easiest-to-use and best-
selling plastics!
Poly 15-Series - Strong plastics with varying densities:
some are like thermoplastics, others like stone.
Poly PT Series - Strong, fast-curing, flame-retardant
plastics for prototyping and model making. Also avail-
able in low-viscosity, fast-curing rubber formulations.
Request Technical Bulletin for details.
Poly-Optic® 14 Series - Water clear, non-yellowing cast-
ing resins for speciality applications demanding clear,
bubble-free castings.
PolyFoam™ Series - Low viscosity, 1:1 mix ratio, fast-
setting rigid and flexible foams.
Poly LiteCast™ - Easy, 1:1 mix ratio plastic with a wood-
like density.
Poly Plasti-Flex - Innovative flexible plastic for architec-
tural moldings that bend, props and more.
Polygel® Plastic-75 - Thickens to a paste upon mixing
and cures in 2-4 hours. Makes great mold shells fast.
Polygel® Shell - A sprayable plastic for creating mold
shells, sprayed-up castings or surface hardcoats.
Polypoxy® Resins & Poly Cures - Epoxy systems for
creating various castings including decorative bonded
bronzes and tools that can withstand high heat.
CURING
Castings should be allowed to remain in the mold until thorough-
ly cured. Parts demolded too soon may be subject to deformation.
Use of pre-warmed molds will hasten curing. Mold shells should
not be demolded until fully cured to prevent distortion or warping.
Check product labels or technical bulletins to determine appropri-
ate demold times. To reach full hardness in the specified demold
time, temperature should be above 77°F (25°C). At lower temper-
atures, more time may be needed to reach full hardness. Curing
below 65°F (18°C) is not recommended. For most Polytek plas-
tics, final cure properties are obtained in within 7 days.
ADDITIVES & ACCESSORIES
Polytek offers various additives and accessories that can be used
to vary the properties of the cured plastics and/or make using the
plastics easier.
• Accelerator/Retarder - Specially formulated chemical accel-
erators or retarders can be added to Polytek liquid plastics to
vary the cure time.
• Fillers - Dry fillers or metal powders can be added to Polytek
liquid plastics to vary the density and look of the cured pieces.
Also, fillers can be added to make the liquid plastic thicker
(i.e., for brush-on or trowel application).
(610)559-8620 • (800)858-5990

• Foamer - A chemical foamer can be added to some liquid
plastics to turn them into foams.
• Colors - PolyColors can be added to liquid plastics (see p. 61).
• Barrier Coat - A barrier coat (i.e., Barrier PF) is a fast drying,
lacquer-like primer that is sprayed into a silicone mold and
allowed to dry prior to pouring plastic. The plastic cures
against the barrier coat and comes out on the plastic casting
resulting in a primed part. Using a barrier coat often extends
mold life.
To learn more about additives, refer to product-specific technical
bulletins or call Polytek Customer Service. Additives and acces-
sories for Polytek plastics are listed in the box to the right.
FINISHING
Many cured plastics yellow slightly and chalk when exposed to
sunlight and, therefore, should be painted or sealed for exterior
use. If they are to be painted or coated, adhesion of the coating
should be checked carefully over a period of time to determine
that it is satisfactory for the intended use. If all mold release is
removed by detergent washing, most oil paints work well.
Castings can be drilled, sanded and machined.
CLEAN UP
Casting Plastics/Resins 4
eye contact, flush with water for 15 minutes and call a physician.
Use only with adequate ventilation. Polytek plastics are not to be
used where food or body contact may occur. Plastics burn readily
when ignited. Care should be taken with sanding dust and other
easily ignitable forms of these products.
STORAGE LIFE
Polytek liquid plastics can be stored for at least six months in
unopened containers stored at room temperature (60-90°F). Cured
plastics will last indefinitely, but may discolor as noted above.
In order to maintain dimensions, Poly Plastic mold shells must be
stored in temperatures <100°F. Also, the shells must not be dis-
torted in storage (e.g., no heavy objects placed on top).
POLYTEK ADDITIVES & ACCESSORIES
Poly-Optic® 14X Catalyst
1 oz, 1 pt (1.0 lb)

Casting Plastics
Tools should be scraped clean before the plastic is hard. Poly-Optic® 14R Retarder
Denatured ethanol is a good cleaning solvent, but it must be han- 1 pt (1.0 lb)
dled with extreme caution owing to its flammability and health
Part 15X Catalyst
hazards. Work surfaces can be waxed or coated with Pol-Ease
1 oz, 1 pt (1.0 lb), 1 gal (8.0 lb)
2300 Release Agent so cured rubber can be removed.
Part 15F Foamer
SAFETY 1 oz, 1 pt (1.0 lb), 1 gal (8.0 lb)
Before use, read product labels and Material Safety Data Sheets.
Poly UV Additive
Follow safety precautions and directions. Contact with uncured
4 oz, 1 pt (1.0 lb)
products may cause eye, skin and/or respiratory irritation. Avoid
contact with skin and eyes. If skin contact occurs, remove with Bronze Powder
waterless hand cleaner or alcohol then soap and water. In case of 2.0 lb can, 10 lb can, 110 lb can
Cab-O-Sil®/Fumed Silica
5 gal, 1 bag (10 lb)
OTHER SUPPLIERS FOR FILLERS Poly Fiber II
3M - Lightweight fillers, Glass Bubbles 5 gal, 1 bag (10 lb)
(800) 541-6752
Pol-Ease® 2300 Release Agent
Ball Consulting ltd - Brass, copper and silver powders 12-oz can, case of 12 cans
(800) 225-2673 Pol-Ease® 2500 Release Agent
Imerys Inc. (formerly Georgia Marble Co.) - Marble powders (Cleanable/Paintable)
(888) 277-9636 12-oz can, case of 12 cans
Pol-Ease® PF Release Agent
Mahogany Co. - Various fillers
1 qt (2.0 lb), 5 gal (40 lb)
(609) 625-8101
Barrier PF Barrier Coat
PQ Corp. - Lightweight fillers, Extendospheres, Q-cells
1 qt (2.0 lb), 5 gal (40 lb)
(800) 252-0039
Poly Purge™
The R.J. Marshall Co. - Aluminum Tihydrate, OnyxFill, etc. 10-oz can, case of 12 cans
(248) 353-4100
PolyColors
Trelleborg Fillite Inc. - Hollow ceramic microspheres Red, Green, Yellow, Blue, Brown & Black
(770) 729-8030 4-oz bottle (0.25 lb), 1.0 pint (1.0 lb)

47
www.polytek.com
 4 Casting Plastics/Resins

EasyFlo™ Series Liquid Plastics

DESCRIPTION: EasyFlo™ Liquid Plastics are excellent for cast-
ing decorative objects, production parts, tools, models, duplicate FEATURES
masters and more. EasyFlo systems consist of two parts (A and B) • Easy 1:1 mix ratio by volume
that, after mixing, quickly cure to tough polyurethane plastics. • Extremely low viscosity -- pours like water
Since Parts A and B are super- low viscosity liquids, they are easy • Sets fast with rapid demold
to mix, provide excellent detail penetration, and make bubble-free • Reproduces finest details
castings without vacuum degassing or pressure casting techniques.
• Tough, non-brittle formula
Rapid demold times make EasyFlo ideal for high-volume, fast-
cast applications. Choose the EasyFlo Liquid Plastic that’s best for • Excellent bubble release without vacuum or pressure
your application: • Readily accepts high filler levels
• EasyFlo 60 pours like water, so making bubble free parts is • Low odor
easy and fast (2-min working time, 10-min demold).
• EasyFlo 95 is useful when longer working time (5 min) is CURING: See p. 46.
needed to complete a pour. For thin parts, demold time is ADDITIVES: Various fillers (bronze powder, microballoons, cal-
longer and molds may need to be preheated (100-120°F) to cium carbonate, sand, granite, etc.) can be added as desired. Fillers
reduce surface bubbles and speed demold. must be thoroughly dried before mixing with resin.
• EasyFlo 120 is best for rotocasting or slush casting to create PolyColors (see p. 61) can be added to EasyFlo Part B before mix-
hollow parts. Hollow parts are nearly unbreakable! ing with Part A to create plastic of any color desired.
• EasyFlo Clear cures to a pale amber color. Add PolyColors to FINISHING: See p. 47.
make transparent, colored castings. It’s excellent in applications
CLEAN UP: See p. 47.
Casting Plastics

using fillers intended for visual appeal (e.g., bronze). Heated

molds and pressure casting techniques are recommended. SAFETY: See p. 47.

MOLD PREPARATION: See p. 46. These bronze castings were

MIXING: Measure equal volumes of A and B into a mixing con- created quickly and easily by
tainer such as a polyethylene pail. Mix immediately and thor- mixing bronze powder with
oughly for one minute. See p. 46 for more information. EasyFlo™ 60 Liquid Plastic.
Large castings such as this
PHYSICAL PROPERTIES 10-inch tall Zeus head can be
rotocast with EasyFlo 120 to
EasyFlo™ Product 60 95 120 Clear create hollow parts weighing a
Mix Ratio, By Volume 1A:1B 1A:1B 1A:1B 1A:1B fraction of the weight of solid
castings.
Mix Ratio, By Weight 100A:90B 100A:90B 100A:90B 100A:90B
Hardness, Shore D 65 65 65 72 Note on Cold-Cast Bronze
Bronze and other metal powders are rather expensive; but only a thin
Pour Time (min; 1-lb mix) 2-2.5 5 2-2.5 2-2.5
coating of resin mixed with bronze need be brushed or slush-cast
Demold Time (min) 15-30 20-60 15-30 15-30 against the face of the mold. Estimate the volume of liquid resin and
Specific Gravity 1.03 1.03 1.03 1.03 bronze required by considering the surface area to be covered by the
thinnest possible layer. If needed, multiple mixes can be made and
Cured Color White Off White White Amber patched one against the other before they fully cure. The recipe for
Initial Mixed Viscosity (cP) 60 95 120 110 the EasyFlo 60/bronze powder mix is as follows. Mix 1 part (by vol-
ume) EasyFlo 60 A with 1 part (by volume) EasyFlo 60 B and blend
Specific Volume (in /lb)
3
26.9 26.9 26.9 26.9
for a few seconds. Then add 2 parts (by volume) bronze powder to
Maximum Exotherm (°F) 230 206 200 208 the mixed EasyFlo and mix well to wet the powder. This mix will be
thick and may not flow into all the mold detail, so brushing may be
needed. Once the face of the mold is evenly coated with a thin layer
PACKAGING
of resin/bronze it can be back-filled with a heavy, solid pour resin
Product(s) Part A (lb) Part B (lb) Unit such as 15-3X. 15-3X resin will make it "feel" like bronze without
the cost of filling the entire space with expensive bronze powder.
1 qt (2.0) 1 qt (1.8) 3.8 lb Once cured, the casting can be removed and burnished with 0000
EasyFlo 60, 95, 1 gal (8.0) 1 gal (7.2) 15.2 lb steel wool. Apply a patina by spraying green and black oil-based
120, & Clear 5 gal (40.0) 5 gal (36.0) 76.0 lb paint and wiping with mineral spirits or use a cold chemical patina
such as Super Antik 40. The results can be amazing!
55 gal (450) 55 gal (405) 855 lb

48
(610)559-8620 • (800)858-5990
 Casting Plastics/Resins 4
Poly 15 Series Liquid Plastics
DESCRIPTION: Poly 15 Series Liquid Plastics are excellent for
casting decorative fixtures, production parts, tools, models, pat- FEATURES
terns, duplicate masters, mold shells and more. Poly 15-6, 1510, • Easy -- 1:1 mix ratio formulations
1511, 1512 and 1512X Plastics have the feel and density of wood • Reproduces fine details
or thermoplastics. Poly 15-3 and 15-3X Plastics resemble stone.
• Can be machined, drilled, sanded
Poly 15-8 is an aluminum-filled system that is ideal for applica-
tions where heat resistance and thermal conductivity are required • Tough and hard, but not brittle
(i.e., vacuum forming). Poly 15-6, 1511 and 1512X can be mixed • Lightweight for mold shells
with Poly Fiber II to create tough, lightweight mold shells. With
• Low shrinkage upon cure
proper equipment and acceleration, Poly 1512 can be sprayed for
hardcoating or to make sprayed-up castings. If water-clear, non-yel- • Air bubbles rise and break
lowing plastics are needed, consider Poly-Optic® products (p. 51). • Long working time or instant set with 15X
MOLD PREPARATION: See p. 46. • Low odor formula
MIXING: See p. 46. • Castable in large masses
CURING: See p. 46. • Sprayable for hardcoating
ADDITIVES: Part 15X Catalyst increases the speed of curing (see
Add fillers as needed to vary the density and appearance of the
box on next page). Stir Part X into Part B before adding Part A. A
cured plastic. Microballoons can be added to create a wood-like,
few drops in a 1-lb mix speeds the cure significantly. Exotherm
density. Other fillers include metal (e.g., bronze) or stone (e.g.,
(heat of reaction; see p. 6) and thus shrinkage may be increased.
calcium carbonate) powders. Add fillers after Parts A and B are
Experiment to determine the best amount of Part X to use, but

Casting Plastics
mixed. Fillers must be thoroughly dried before mixing with resin.
never use more than 1% Part X of the total weight of the mix or
the final physical properties may be affected. PolyColors (see p. 61) can be added to some 15 Series Part Bs
before mixing with Part A to create colored plastics.
Part 15F Foamer can be added to Poly 15-6 and 1510 to create
rigid, open-cell foams with densities as low as 6 lb/ft3. Part F FINISHING: See p. 47.
Foamer should be stirred into the Part B before adding Part A. STORAGE: In order to maintain dimensions, Poly Plastic mold
Experiment to determine the best amount of Part F for the appli- shells must be stored in temperatures <100°F. Also, the shells
cation at hand, but never use more than 3% Part F of the total must not be distorted in storage (e.g., no heavy objects placed on
weight of the mix or the final physical properties may be affected. top). See p. 47.
For self-skinning foams, consider PolyFoam™ products (see p. 53).
CLEAN UP: See p. 47.
If a paste-like consistency is needed for application, add Poly
SAFETY: See p. 47.
Fiber II to thicken the mix
PHYSICAL PROPERTIES
15-3/15-3X 15-6 15-8 1510 1511 1512/1512X
Mix Ratio (By Weight) 1A:1B 1A:1B 26A:100B 1A:1B 1A:1B 1A:1B
Hardness, Shore D 80 72 80 71 71 71
15 (15-3) 22 (1512)
Pour Time, 1-lb mix (min) 5 30 19 8-10
5 (15-3X) 5 (1512X)
Maximum Exotherm, 1-lb mass 122°F (50°C) 203°F (95°C) 131°F (55°C) 264°F (129°C) 251°F (122°C) 251°F (122°C)
Demold Time (hr) 12 (15-3) 1-16 (1512)
1-3 1-16 1-16 0.5-1
(varies with 15X) 1 (15-3X) 0.5 (1512X)
Specific Gravity 1.53 1.08 1.57 1.08 1.10 1.10
Color, Cured Tan Tan Gray Off-White White White
Viscosity, 2-min after mix (cP) 2,000 800 6,000 160 400 400
Specific Volume (in3/lb) 18 26 17.6 26 25.1 25.1
0.0002* (15-3)
Shrinkage Upon Cure (in/in) 0.003* 0.0002 Very low* Very low* Very low*
0.008* (15-3X)
*Shrinkage is primarily caused by gelling while hot then cooling. Parts that cure with minimal temperature rise usually exhibit minimal shrinkage.

49
www.polytek.com
 4 Casting Plastics/Resins
Polytek ® is proud to share
its hometown, Easton, PA,
with Crayola Inc. The larg-
er-than-life crayons falling
from the roof of the
Crayola Factory Visitors
Center were cast in Poly
15-6 Liquid Plastic.

Poly 15 Series Liquid Plastics reproduce the finest detail. Fillers

can be added to Poly 15 Series Liquid Plastics to create castings
with varying looks and densities.

Effect of 15X Addition on Pot-Life and Demold Times

% 15X Pre- Pot-Life Demold Time Shore D Shore D

Mixed with B (1-lb Mass) (¼-in casting) @ Demold @ 24 hr

0.00 26 min 225 min 45-55 76

Casting Plastics

0.10 8 min 16 min 38-55 76

0.25 3 min 8 min 38-55 76

0.50 1.75 min 6 min 38-55 76

Note on Spraying Poly 1512X Plastic

Poly 1512X accelerated with Poly 74/75 Part X can be sprayed
using low cost spray equipment, such as Plas-Pak guns, or more
sophisticated spray systems. The amount of 74/75 X required varies
depending on temperature. Adding 1.35 g of 74/75 Part X to 1 lb of
1512X Part B yields a 10 second working time sprayable plastic.
Experiment to determine the amount of 74/75 X needed. Only spray Mother Earth Float in Macy’s 74th Annual Thanksgiving Day
in well ventilated areas such as a spray booth. For more information Parade was hard-coated with Poly 1512X Liquid Plastic to create
on Plas-Pak spray equipment, see p. 64. a tough, paintable surface. The float, sponsored by Maytag
Neptune Washer, was built at Macy’s Parade Studio.

Packaging
15 Series Product
Unit Sizes (lb) Part A (lb) Part B (lb)
5.0 1 qt (2.5) 1 qt (2.5)
Poly 15-3, 15-3X
20.0 1 gal (10) 1 gal (10)
Mix Ratio 1A:1B
100 5 gal (50) 5 gal (50)
1 qt (2.0)
4.0 1 qt (2.0)
1 gal (8.0)
Poly 15-6, 1510, 1511, 1512, 1512X 16.0 1 gal (8.0)
5 gal (40.0)
Mix Ratio 1A:1B 80.0 5 gal (40.0)
11 x 5 gal (450)
900 55 gal (450)
55 gal (450) 1510 only!
3.2 1 pt (0.7) 1 qt (2.5)
Poly 15-8
12.0 1 qt (2.5) 1 gal (9.6)
Mix Ratio 26A:100B
48.5 1 gal (10.0) 5 gal (38.0)

50
(610)559-8620 • (800)858-5990

®
Poly-Optic 14 Series Clear Casting Resins
DESCRIPTION: Poly-Optic® 14 Series Casting Resins are two-
component, polyurethane systems that were formulated specifically
for applications where optical clarity is a must. Use Poly-Optic
plastics for casting decorative objects, production parts, models
and more. Castings are clear like water; however, PolyColor dyes
can be added to obtain clear, colored castings. Poly-Optic systems,
with their low viscosities and long pot-lives, provide for easy mix-
ing, excellent detail penetration and easy degassing resulting in
bubble-free castings when vacuum or pressure casting techniques
are employed.
Poly-Optic® 1410 cures to a hard plastic that is virtually
unbreakable. Cure 1410 at room temperature and, for optimum
physical properties, post cure at 150°F.
Poly-Optic 1411 is an easy 1A:1B, by volume system that cures
® bubble-free Poly-Optic castings, vacuum degassing or pressure
quickly to a super-strong, hard plastic. Poly-Optic 1411 develops
hardness and can be demolded more quickly than 1410. It also has
a higher heat deflection temperature, which is useful in certain
prototyping applications.
Poly-Optic® 1420 cures to a tough, impact- and heat-resistant
plastic that can be polished and machined. For strong plastic, heat
Casting Plastics/Resins 4
FEATURES
• Crystal clear, like water
• Low viscosity for easy pouring
• Reproduces fine detail
• Can be machined, drilled and sanded
• Long working time
• Low shrinkage upon cure
MIXING: See p. 46 for information on proper mixing.
VACUUM DEGASSING OR PRESSURE CASTING: For
casting must be employed. See page 16 for more information on
vacuum and pressure. A light spray of Pol-Ease 2300 or quickly
passing the flame of a torch over the back of the casting helps
break any bubbles on the back of the pour.
CURING: Poly-Optic 1410, 1411 and 14-70 cure at room tem-
perature. For castings less than 0.25-inch thick, 1411 is recom-

cure 1420 at 150-180°F. For brittle, glass-like castings, cure at
room temperature.
Poly-Optic® 14-70 is a firm rubber. Blend 1410 and 14-70 to
achieve any hardness between Shore D85 and Shore A70. (See
table on next page.)
MOLD PREPARATION: Poly-Optic products reproduce minute
detail from a mold or pattern but may stick or foam when poured
on improperly prepared surfaces. A trial casting on a surface fin-
ish similar to the final mold should be made to avoid damaging a
valuable mold. Polyethylene and silicone rubber molds, such as
PlatSil® 71and 73 Series products, do not require a release agent.
[CAUTION: Condensation-cure silicones (i.e., TinSil® 70 Series)
are not recommended for casting Poly-Optic since residual alcohol
may inhibit the cure or result in hazy castings.] Latex,
polyurethane or metal molds must be dry and require a coat of a
suitable release agent, such as Pol-Ease® 2300 Release Agent. For
optically clear castings, use highly polished masters to create
molds with excellent surface quality.
Casting Plastics
mended because it can be demolded more quickly in thin sections.
For thinner castings, or when using Poly-Optic 1410 for thin parts,
add Part 14X Catalyst or heat cure (8 hr at 140-150°F). Castings
greater than 0.5-in thick do not require heat or 14X, but the addi-
tion or use of either will speed up the curing process considerably.
Poly-Optic 1420 cures in 8 hours at 150°F, or 16 hours for opti-
mum physical properties. If cured at a higher temperatures, parts
may be demolded sooner (e.g., 30 min at 180°F depending on size.
For brittle, glass-like parts, cure 1420 at room temperature.
Wash mold release from surfaces prior to painting or bonding.
ACCELERATING CURE SPEED: Mix Poly-Optic 14X
Catalyst into Part B prior to adding Part A to accelerate the gel and
cure time for Poly-Optic resins. 14X is recommended for castings
less than 0.5-in thick. For best results, mix Parts A and B, degas if
required, then add 14X and degas again if necessary. Adding 0.5%
14X to the total mix weight speeds the cure significantly. For
example, 0.5g 14X in a 100g mix of Poly-Optic 1410 halves the

PHYSICAL PROPERTIES
Poly-Optic® Product 1410 1411 1420 14-70
Mix Ratio 3A:2B, by weight 1A:1B, by volume 2A:1B, by weight 4A:5B, by weight
Hardness (Shore A or D) D80 D80 D85 A70
Pour time (min), 2-lb mix 15 9 15 15
Maximum exotherm, 2-lb mass 265°F (129°C) 228°F (109°C) 311°F (155°C) 190°F (88°C)
Demold time (hr)* 2 (1-in thick)* 0.5 (.5-in thick) 8 @150°F/0.5 @175°F 24-48
Specific gravity 1.07 1.07 1.05 1.06
Viscosity, 2 min after mixed (cP) 700 600 250 340
Specific Volume, in3/lb 27.5 27.5 27.5 27.5
* Demold time varies with thickness of casting and the amount of Part 14X Catalyst added.

51
www.polytek.com
 4 Casting Plastics/Resins
pour and cure time. Exotherm (heat of reaction; see p. 6) and thus
PACKAGING
shrinkage on cooling is also increased. Experiment to determine
the best amount of 14X to use, but do not use more than 1% 14X Product Unit Weight (lb)
because final physical properties may be affected. ®
Poly-Optic 1410 10.0
RETARDING CURE SPEED: Poly-Optic 14R Retarder slows Mix Ratio 3A:2B 60.0
the cure of Poly-Optic systems. Slowing the cure also reduces
®
exothermic heating that can cause distortion, waviness and shrink- Poly-Optic 1411 3.8
age especially in castings >0.5-inch thick. Add 1.5% 14R to the Mix Ratio 1A:1B (By Volume) 15.2
total mix weight of Poly-Optic 1410 to increase pot-life from 15 76.0
minutes to 70 minutes. Add 1% 14R to 1411 to double the work- ®
Poly-Optic 1420 6.0
ing time from 9 to 18 minutes. Depending on the size and mass of
Mix Ratio 2A:1B 24.0
the part, post curing Poly-Optic 14-70 and 1410 parts in the mold
120.0
at a minimum of 140°F for 12 to 16 hours may be necessary. The
®
extended pot-life creates a lower exotherm upon curing, allowing Poly-Optic 14-70 14.4
larger castings to be made without distortion. Never use more than Mix Ratio 4A:5B 72.0
4% since the system may not cure properly. See table to right
regarding 14R addition to 1410.
®
COLORS: Add PolyColors (see p. 61) to 14 Series Part B before Poly-Optic 1410 Gel Times with 14R Addition
mixing with Part A to create clear plastics of any color.
Weigh, add and mix 14R into 1410B. Weigh and add 1410A,
EXTERIOR USES: Although Poly-Optic 1410, 1411 and 1420 plus one additional part A for every part of 14R used in the
are non-yellowing formulas, they are not recommended for long- 14R/1410B premix. Mix well. Pour into prepared mold. Degas
term exterior use. Poly UV Additive can be added to improve or pressure cast for bubble-free castings.
durability for exterior applications. Add 1% UV Additive to the
Casting Plastics

total mix weight of Poly-Optic to reduce the onset of chalking and 1410Part A 100 100.5 101 101.5
pitting of the outside surface for ~2 years. Add 3% Poly UV
Additive to achieve good exterior stability beyond 5 years. 1410Part B 66.6 66.6 66.6 66.6

CLEAN UP: See p. 47. 14R 0 0.5 1.0 1.5

SAFETY: See p. 47. Gel Time
15 21 40 72
STORAGE LIFE: Poly-Optic liquids can be stored for at least 6 (min)
months in unopened containers stored at room temperature. Poly-
Optic Part As may crystallize slightly or become viscous during
storage. If crystallization occurs warm the container to 100-120°F
until crystals dissipate. Cool to room temperature before use. ®
Blending Poly-Optic 1410 and 14-70* for Various
Hardnesses

The clarity of Poly-Optic® 1410 Part A 100 100 100 100 100
1410 is remarkable. This
amazing negative sculp-
ture comes to life with 1410 Part B 52 42 33 23 13
overhead lighting.
14-70 Part B 25 44 62 82 100

Shore A
NA NA 95 88 75
Hardness
Poly-Optic® 1410 Liquid
Shore D
Plastic was poured into 87 77 60 37 25
Hardness
a cylindrical mold to
form a rod, which was * Note: Premix Poly-Optic 1410 and 14-70 Part Bs prior to mix-
softened in hot water ing with Part A. Poly-Optic 1410 and 14-70 Part As are the
and coiled around a same; therefore, premixing Part As is not necessary.
mandrel. Once cooled, it
holds its shape to form a
tough, spring-like coil.

52
(610)559-8620 • (800)858-5990
 Casting Plastics/Resins 4
PolyFoam™ Series Casting Foams
DESCRIPTION: PolyFoam™ Series Casting Foams consist of liq-
uid Parts A and B that, after mixing, form self-skinning foams. FEATURES
PolyFoam can be used to cast rigid or flexible objects with densi-
• Easy 1:1 mix ratios
ties in the range of 3-20 lb/ft3. Considered PolyFoam for produc-
tion of decorative objects, lightweight mold shells, production • Self-skinning foams
parts, tools, models, patterns, fixtures, duplicate masters and gen- • Rigid and flexible foams
eral tooling use. PolyFoam systems do not contain toluene diiso-
• Densities range from 3 to 20 lb/ft3
cyanate, MOCA, heavy metals or HCFCs, and are practically
odorless. PolyFoam R-2, R-5 and R-8 are rigid foams. PolyFoam
F-5 is flexible for casting soft parts.
MOLD PREPARATION: See p. 46. Be sure that rubber molds
POLYFOAM™ PHYSICAL PROPERTIES
used with PolyFoam are stiff enough so as not to distort when sub-
jected to packing pressures. Use a suitable barrier coat such as R-2 R-5/R-8 F-5
Barrier PF to extend mold life when using rigid foams. If Barrier
Mix Ratio
PF is used, apply Pol-Ease® PF Release Agent to the mold prior to 1A:1B 1A:1B 1A:1B
(By Weight or Volume)
applying Barrier PF.
Mix Viscosity (cP) 500 1100 1400
MIXING: See p. 46 for general guidelines. Combine Parts A and
B and mix immediately with a Turbo mixer or other high speed Cream Time (sec) 30 45 45
mixer for 30 seconds. Pour mix into cavity as quickly as possible Rise Time (min) 3 2 3-5

Casting Plastics
since foaming starts immediately. If too much time elapses, the
foam will rise in the mixing container and the mix may be lost. Tack-Free Time (min) 10 3 25
Once containers of Parts A and B are opened, they should be used Demold Time (min) 30 10-15 30-60
or resealed tightly as atmospheric moisture contamination may 5 (R-5)
degrade product integrity causing excess foaming, pressure build Free-Rise Density (lb/ft3) 2.5 5
8 (R-8)
up and poor cure properties. To improve shelf stability of the liq-
Molded Density (lb/ft3) 4-8 8-20 8-15
uid products, use Poly Purge to displace moist air in opened A and
B containers before resealing.
CURING: Packing PolyFoams to a minimum of 2-3 lb/ft3 above
their free-rise density is recommended to achieve good surface Note on PolyFoam Compaction Calculation:
detail and mold fill. A lid with small vents to allow air to escape
Using the desired density or compaction in pounds per
as foam rises should be firmly clamped in place prior to rise. Once
cubic foot (lb/ft3), divide that number by 1728 cubic inches
foam begins rising, avoid stirring or other movement that will (in3). The result will be a decimal “factor” (0.004576 or simi-
cause cells to collapse. Castings should be allowed to remain in lar). Then multiply the volume of the space you want to fill
the mold until thoroughly cured. Parts demolded too soon may be with foam (in in3) by the “factor.” The result equals the
subject to deformation. For best casting results, the mold should pounds of PolyFoam liquid to prepare.
be warmed to between 75°F and 85°F prior to casting the first part.
Once a mold is heated and cycled, it will maintain heat for con-
tinued production. Barrier PF, sprayed and allowed to dry in the mold before casting
will result in a pre-primed part upon demolding.
FINISHING: See p. 47 for general guidelines. When casting rigid
foams, the use of an appropriate primer/barrier coat, such as CLEAN UP & SAFETY: See p. 47.

POLYFOAM™ PACKAGING

Components
Unit Weight (lb)
Part A (lb) Part B (lb)

4.0 1 qt (2.0) 1 qt (2.0)

PolyFoam™ R-2, R-5, R-8 and F-5
16.0 1 gal (8.0) 1 gal (8.0)
Mix Ratio 1A:1B
80.0 5 gal (40.0) 5 gal (40.0)
(By Weight or Volume)
900 55 gal (450) 55 gal (450)

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 4 Casting Plastics/Resins

Poly LiteCast™ Liquid Plastic

DESCRIPTION: Poly LiteCast™ Liquid Plastic has a wood-like
density and can be used to produce decorative objects, tools, mod- FEATURES
els, patterns, fixtures and duplicate masters. Poly LiteCast repro- • Wood-like density
duces fine details from molds and can be drilled, sanded and • Easy 1:1 mix ratio by weight or volume
machined. • Safe and easy to machine, contains no silica
MOLD PREPARATION: See p. 46. • Tough and hard, but not brittle
MIXING AND CURING: See p. 46. [Note: Stir both Parts A and
B before use since the filler in Poly LiteCast rises to the top.] PHYSICAL PROPERTIES
ADDITIVES: To accelerate the cure, add Part 15X Catalyst. A Mix Ratio, By Weight or Volume 1A:1B
few drops of Part 15X added to one-pound of mixed Parts A and Hardness, Shore D 55
B speeds the cure significantly. When using Part 15X, exotherm Pour Time, 1 lb. mix (min) 5
(heat of reaction) increases and can result in shrinkage of the cast Demold Time (hr) (varies with 15X) 1
part. Experiment to determine the right amount of Part 15X to use Viscosity, 2 min after mix (cP) 2,480
but never use more than 1% of the total weight of the mix or the
Specific Volume (in3/lb) 35
final physical properties may be affected.
If a paste-like consistency is needed for brush-on or trowel appli-
PACKAGING
cation, add Poly Fiber or Cab-O-Sil® to thicken the mix.
Unit Weight Containers
PolyColors (see p. 61) can be added LiteCast Part B before mixing
(lb) Size Net Weight (lb)
Casting Plastics

with Part A to create plastic of any color.

A B A B
CLEAN UP: See p. 47.
3 1 qt 1 qt 1.5 1.5
SAFETY: See p. 47. 12 1 gal 1 gal 6.0 6.0
60 5 gal 5 gal 30.0 30.0

Poly Plasti-Flex™ Liquid Plastic

DESCRIPTION: Poly Plasti-Flex™ Liquid Plastic is flexible
making it ideal for casting decorative trim and molding that needs FEATURES
to be mounted on a curved or uneven surface. Plasti-Flex can also • FLEXIBLE!
be used to make special effects castings and props and impact- • Wood-like density
resistant forms, tools and parts. Plasti-Flex has a wood-like densi- • Safe and easy to machine, drill or sand (no silica)
ty and can be drilled, sanded, nailed and screwed.
MOLD PREPARATION: See p. 46.
MIXING AND CURING: See p. 46. PHYSICAL PROPERTIES
Mix Ratio, By Weight or Volume 35A:100B
ADDITIVES: PolyColors (see p. 61) can be added Poly Plasti-
Flex Part B before mixing with Part A to create plastic of any color. Hardness, Shore A 90
Pour Time, 1 lb. mix (min) 3
CLEAN UP & SAFETY: See p. 47.
Demold Time (min) ~15
Viscosity, 2 min after mix (cP) 3,000
Specific Volume(in3/lb) 34
PACKAGING
Unit Weight Containers
Poly Plasti-Flex architectur-
(lb) Size Net Weight (lb) al trim casting. The casting,
A B A B which is held in a curved
8.1 1 qt 1 gal 2.1 6.0 position, can be easily
38.5 1 gal 5 gal 10.0 28.5 mounted on a curved sur-
face.
192.5 5 gal 5 x 5 gal 50.0 142.5

54
(610)559-8620 • (800)858-5990
 Casting Plastics/Resins 4
®
Polygel Liquid Plastics
U.S. Patent # 5,128,433

DESCRIPTION: Polygel® Plastics produce strong, light-weight

mold shells and are ideal for shells built up with a brush or spat- FEATURES
ula on vertical or overhead surfaces. Sprayable Polygel Shell is
• Easy -- 1:1 mix by weight or volume
ideal for large surface area applications where brushing may be
impractical. Polygel products consist of liquid Parts A and B, that • Fast -- same-day mold shells
after mixing 1:1 by weight or volume, immediately self-thicken. • Strong and lightweight
MIXING & CURING: See p. 46 for general guidelines. • Color-coded mix indication
For Polygel Plastic-75, mixing of Parts A and B should be rapid • Long life for molds and shells
and thorough. Most mixing should be completed within ten sec-
onds or so before gelling begins and while the mix is still liquid
to minimize air entrapment. Mix only enough that can be applied This photo shows
during the working time. Polygel Plastic-75 generates heat when Polygel ® Plastic-75 being
mixed, so use rubberized cotton gloves to ease handling of the hot applied with a spatula
container. Once mixed, dumping the thickened mix on the surface over a Polygel® 35 rubber
to be coated and quickly spreading into a thin layer will cool the mold to create a rigid
mass and extend working time by a minute or two. Do not try to plastic mold shell. Notice
demold Polygel Plastic-75 until adequate cure time has elapsed as that the uncured plastic is
it may be somewhat brittle. thixotropic -- it can be

Casting Plastics
Polygel Shell Plastic is a rapid-setting liquid plastic designed for moved around the mold
spray applications. Hand mixing is not recommended. When surface but does not drip
meter-mixed and sprayed 1:1 by volume, Polygel Shell gels sev- or sag.
eral seconds after contacting the surface being covered, then
remains in a workable grease-like state for 1 minute. Shells or
castings can be demolded in 2 hours depending upon thickness
and ambient temperature. Thicknesses <¼-inch may require The photo below shows
longer cure time. Thin, tough coatings can be applied to many the brushed Polygel® 35
surfaces such as carved foam. Mold shells should be approxi- mold supported by its
mately ¼-inch thick. When spraying a mold shell, thicknesses thin, lightweight Polygel®
>½-inch are not recommended as shrinkage can occur upon cur- Plastic-75 shell. The hol-
ing and cooling. For additional strength, lay fiberglass strand or low, rotocast part was
mat while applying Polygel Shell. For very large shell sections, cast using EasyFlo™ 120
supporting structures such as boards or metal rods can be attached and swirled PolyColor
to prevent warping or damage during use. dye to achieve a marbled
appearance.
STORAGE: In order to maintain dimensions, Poly Plastic mold
shells must be stored in temperatures <100°F. Also, the shells
must not be distorted in storage (e.g., no heavy objects placed on
top). See p. 47.
CLEAN UP & SAFETY: See p. 47.

PACKAGING
Mix Ratio 1A:1B (by weight or volume)
Unit Weight (lb)
4
16
Polygel Plastic-75
80
900

Polygel Shell 80

55
www.polytek.com
 4 Casting Plastics/Resins

Polypoxy Resins ®

DESCRIPTION: Polypoxy® Resins and Poly Cure Hardeners are

liquids that, after mixing in proper ratio, cure at room temperature
to high-strength plastics. Resins can be cured with various cura- APPLICATIONS
tives enabling users to select the best system for a particular use.
Polypoxy ® 1010 + Poly Cure 1212
The mix ratio for each curing agent and resin blend varies. For
best results, carefully weigh the components. Bonded bronze

Polypoxy ® 1010 is a clear resin for use with fast Poly Cure 1212 Polypoxy ® 1010 + Poly Cure 1220
for small castings such as bonded bronze or with fiberglass or Decoupage coatings and glass bonding
fillers for lay-up and mother molds. Use with Poly Cure 1220 for
decoupage clear coatings, glass bonding and many other uses Polypoxy ® 1030 + Poly Cure 1212
where a nearly colorless, clear, low viscosity resin is required. Small castings and tooling applications
Polypoxy ® 1030 is an aluminum- and mineral-filled resin for Polypoxy ® 1030 + Poly Cure 1230
lay-up or small castings when cured with Poly Cure 1212. For
Larger vacuum molds
larger vacuum forming molds and other tooling uses, cure with
Poly Cure 1230. Parts made with Polypoxy 1030 can be machined,
drilled and burnished with steel wool to a pewter finish.
SURFACE PREPARATION: Polypoxy Resins are adhesives
and bond to many surfaces. If adhesion is not desired, surfaces PACKAGING
must be made non-porous with a suitable sealer, such as wax,
Product Unit Weight (lb) Container
Casting Plastics

PVA, lacquer or other coatings. The surfaces must then be coated

with a release agent such as Pol-Ease 2300. Poly 74 Series rubber Polypoxy 1010 2.0 1 qt
molds require only a light, thorough coating of Pol-Ease 2300 for 9.0 1 gal
excellent release of epoxy castings. Perform a small test cure. 45.0 5 gal
MIXING: Polypoxy and Poly Cure must be mixed in the ratios Polypoxy 1030 3.0 1 qt
shown below. Mix ratios are by weight except for Polypoxy 1010
12.0 1 gal
and Cure 1220, which can be mixed 1:1 by volume. Polypoxy and
60.0 5 gal
Cure must be thoroughly mixed and poured as soon as possible
after mixing to ensure low viscosity and good flow. Watch a clock Poly Cure1212 0.25 4 oz
to avoid being caught with unused, cured material. 2.0 1 qt
HEAT RESISTANT CASTINGS: Polypoxy 1030 offers good Poly Cure 1220 0.25 4 oz
heat resistance. Call Polytek for more information. 2.0 1 qt
CLEAN UP: See p. 47. 8.0 1 gal
SAFETY: Before use, read product labels and Material Safety 40.0 6 gal
Data Sheets. Follow safety precautions and directions. Poly Cure Poly Cure 1230 0.25 4 oz
Hardeners cause severe eye and skin burns. Do not get in eyes or 2.0 1 qt
on skin. WARNING: The epoxy cure reaction is very exothermic 8.0 1 gal
(see p. 6). Do not cast large masses -- doing so can result in a fire!

PHYSICAL PROPERTIES
Polypoxy + Poly Cure 1010 + 1212 1010 + 1220 1030 + 1212 1030 + 1230
Parts Cure per 100 of Polypoxy 15 85 (1:1 by vol) 6 15
Mixed Viscosity(cP) 3,000 3,000 10,000 5,000
Pour Time, 150 g mix @ 77°F (min) 25 30 30 120
Demold Time @ 77°F (hr) 4–8 48 24 24
Maximum Casting Thickness (in) 0.5 1.5 3.0 8.0
Shore D Hardness 95 80 98 95
Specific Gravity 1.13 1.07 1.70 1.70
Specific Volume (in3/lb) 24.5 26.0 16.3 16.3
Density (lb/in3) 0.0408 0.0386 0.0614 0.0614

56
(610)559-8620 • (800)858-5990

Speciality Mold Making & Casting Materials
This section describes a few speciality mold making and casting
materials offered by Polytek. These materials can be used in
conjunction with Polytek’s traditional mold rubber and casting
plastic products, enabling users to tackle virtually any mold
making and casting challenge.
Poly Latex 60
DESCRIPTION: Poly Latex 60 is a one-part, brush-on liquid
that, after multiple coats, builds up to form a tough rubber blanket
mold. Use Poly Latex 60 molds for casting plaster, concrete and
limited casting with some resins.
Poly Latex 60 has better tear strength than synthetic rubbers and
is sometimes preferred for molds that are peeled off the casting
like a sock. However, two-part, synthetic rubbers like Polygel®
products can be brushed on to final thickness in an afternoon and
should be considered as a latex alternative (see p. 36).
MODEL PREPARATION: The model should be free of oil,
grease and dirt. Wood, oil-based clay, stone and glazed ceramics
generally do not require any sealer. Plaster, unglazed ceramics,
copper containing metals, water clay and cement should be sealed
with shellac. Models made of other materials should be patch test-
ed by applying a coat or two of latex to a small area. If the latex
turns dark or sticks after drying, a sealer should be applied.
Models with sharp edges or points may yield a better mold if the
points are dulled slightly by sanding prior to sealing. Firmly
mount the model on a suitable base board (i.e., plywood or a sink
cutout available from kitchen counter shops). Drill a hole through
the base board to allow air to escape from within the model so that
trapped air does not cause defects in the mold.
APPLYING & CURING: Brush a thin coat of latex on the
model. Be careful not to puddle the latex. A gentle stream of air
can help to blow latex into the finest detail and break any bubbles.
Let each coat dry for 4 to 16 hours in a warm, ventilated room.
Drying time depends on temperature and humidity. Warm, dry air
is necessary for fast drying. When dry, the latex loses its milky
appearance, and becomes slightly transparent and amber in color.
Apply the next coat as soon as the first coat is dry. Apply 6 to 30
coats depending on the desired mold thickness. Molds are typical-
ly 1/16- to 1/8-inch thick. For large, flat models, apply latex in a
checkerboard pattern, alternating squares between coats. Since
there is some shrinkage on drying, the patchwork method reduces
stress and warping of the latex as it dries.
Latex can be thickened with ground cork, sawdust or Cab-O-Sil®
in order to fill undercuts. Thickeners must be completely wet out
with latex and applied to the outside surface of the mold. The
thickened latex must be allowed to dry completely as wet spots
trapped in the latex can cause delamination of the mold.
If needed, reinforce latex molds by placing fabric (e.g., muslin,
burlap, polyester) into a coat of wet latex and then saturate with latex.
Allow the fabric coat to dry completely before applying more latex.
www.polytek.com
Speciality Materials 5
Latex - Tough, one-part brushable, castable rubbers
Wax - Castable, carvable version; skin-safe version,
acceptable for body molds
Hydrogel - Safe for skin contact for body molds & life casting
FEATURES
• Brush-on liquid
• Great for casting highly ornamental plaster and concrete
• One part, no mixing or weighing needed
• Tougher than any other mold rubber
For spray application with a cup gun, mix 1 part Poly Latex 60
with 1 part Poly Latex N. Poly Latex N is available in the same
package sizes as Poly Latex 60.
Before removing from the model, the latex must be thoroughly
dry or heat cured. Heat in a warm oven at 110-150°F for 6 to 8
hours to ensure a complete cure. If heat curing is not feasible,
place the mold in a warm area for a week to strengthen the rubber.
Clean up wet latex with soap and water. Dried latex can be soft-
ened with waterless hand cleaner and washed away.
USING THE MOLD: Avoid exposing the mold to oils, grease or
solvents. Molds can be washed with soap and water. Before casting
plaster or cement, wet the mold with a 1% solution of detergent in
water to aid air bubble release from the mold surface. Usually, no
Speciality
Materials
other release is necessary. For resin casting, a release agent such as
Pol-Ease® 2300 or PVA is needed. Most resins shorten the life of a
latex mold -- Polygel® or Poly-Sil® rubber molds may last longer.
SAFETY: Before use, read product label and Material Safety
Data Sheet. WARNING! Latex products contain ammonia and
causes eye and skin irritation. Avoid skin and eye contact. Use
with adequate ventilation. In case of contact, flush eyes with plen-
ty of water for 15 minutes and seek medical attention. Remove
from skin and clothing with soap and water.
STORAGE LIFE: At least 3 months in unopened containers
stored at room temperature (50-70°F). Tightly reseal opened con-
tainers. As latex ages beyond 3 months, it will not cure to as sup-
ple a rubber and shrinkage on drying may increase and toughness
of the mold will decrease. Exposure to temperatures below 40°F
and above 80°F may damage latex, causing irreversible coagula-
tion. DO NOT ALLOW TO FREEZE.
PACKAGING
Unit Weight (lb) Container
2.0 1 qt
8.0 1 gal
40.0 5 gal
400 55 gal
57
 5 Speciality Materials
Poly Latex False Face Compound
DESCRIPTION: Poly Latex False Face Compound is a one-part
pourable liquid that, when poured into a dry, unsealed gypsum
mold, cures to a high-strength, flexible casting rubber. False Face
was formulated to produce flexible hollow parts for uses such as
novelty masks, flexible sculpture and animatronic applications.
MODEL PREPARATION: To cure properly, this product must
be cast into dry, unsealed, porous plaster molds. The user must
determine the suitability of other porous mold materials.
MIXING AND CURING: Shake or stir Latex False Face before
use. Pour into a prepared gypsum mold. Tilting or lightly vibrat-
ing the mold may help eliminate bubbles if the mold contains
complex undercuts or deep details. For a thin skin, pour the excess
latex back into the container immediately. For a thicker skin,
allow the latex to stay in the mold longer before pouring off
excess. A standing time of 15 minutes yields a 3/32-inch thickness
in a dry No. 1 Pottery Plaster mold. Denser plasters are not as
Latex False Face molds can be made
by dipping a dry, porous plaster model
into False Face. The longer the model is
submerged, the thicker the mold. This
technique is only suitable for models
with a shape that won’t trap air when
placed upside down in the False Face
liquid.
Poly Wax 15
Speciality
Materials
DESCRIPTION: Poly Wax 15 is a white, hard, low shrinkage,
mineral-filled wax, which can be cast and carved. When cast, it
replicates the mold surface in detail and finish. Tool cuts are
smooth and lustrous. Dull surfaces can be hand polished with a
soft cloth to a satin luster.
MELTING AND CASTING: Poly Wax 15 softens below 130°F
and is quite fluid at 160°F. Viscosity decreases rapidly as temper-
ature is increased. At 200°F, components of the wax separate
slightly. Mix the melted wax thoroughly before pouring.
Complete mixing is quick and easy to determine visually -- mixed
liquid wax is uniformly colored with no streaks. Use a non-
porous, heat resistant stirrer such as a metal spatula. Pour temper-
atures are typically 210°F-280°F; however, the ideal temperature
is dependent on the mold size, shape and material. Poly Wax 15
holds temperature for a long time, so large or multiple molds can
be filled in a single pour. When slush molding, excessively high
temperatures will cause remelting of layers already laid down and
PHYSICAL PROPERTIES
Softening point 126°F
Use temperature 210 - 280°F
Viscosity @ 100°C (212°F) 116 cP
Density (in3/lb) @ 25°C (77°F) 19.5
@ 100°C (212°F) 21.6
58
FEATURES
• Easy one-part rubber—no mixing or weighing
• Tougher than any other mold rubber
• Good reproduction of fine detail
• Forms hollow castings without roto-molding
absorbent and thicknesses build slower. Allow False Face to dry
in the mold for 24 hours at room temperature. Elevated tempera-
tures accelerate drying time.
Clean up wet latex with soap and water. Dried latex can be soft-
ened with waterless hand cleaner and washed away.
USING THE CASTING: Lightly dust the inside of the casting
with talc in order to prevent the dry rubber from sticking to itself.
Avoid exposing the casting to oils, greases or solvents. Castings
should be stored out of direct sunlight.
SAFETY & STORAGE: Same as Poly Latex 60 (see p. 57).
PACKAGING
Unit Weight Container
2.0 1 qt
8.0 1 gal
40.0 5 gal
FEATURES
• Ideal for prototypes
• Cast carving blanks from rubber molds of rough originals
• Suitable for master models
• Smooth and lustrous surfaces
significantly prolong the procedure. Casting temperatures that are
too low will result in surface bubbles and “knit” marks because
the wax solidifies too rapidly on the mold surface.
Poly Wax 15 can be poured in Poly 74 Series, Poly-Fast 72-40,
Poly-Sil®, Polygel® or Hydrogel® molds. Latex will be softened
by continual pours of Poly Wax 15. Most heat resistant resins and
metal molds are also suitable; however, a small trial casting is
always recommended to be sure castings release satisfactorily
and do not damage the mold material.
SAFETY: Before use, read product labels and Material Safety
Safety Sheets. Hot wax can cause severe burns and ignites easily.
Avoid skin contact. Do not heat with an open flame. Do not heat
above 280°F since vapors can ignite.
STORAGE LIFE: At least 12 months from date of shipment.
PACKAGING
Poly Wax 15 is available in 5-lb blocks
(610)559-8620 • (800)858-5990

Poly Skin-Wax
DESCRIPTION: Poly Skin-Wax is a liquid at temperatures as
low as 125°F and it is somewhat elastic after solidifying. It can be
applied to models using dip or brush-on techniques. Poly Skin-
Wax has been formulated with non-toxic materials and is safe for
skin contact provided temperature is carefully controlled.
MODEL PREPARATION: When making a mold of a body part,
coat skin and hair with baby oil before applying Skin-Wax. Molds
can only be made of body parts that are covered with short and
light hair -- do NOT attempt to make molds from hairy areas. For
most other non-porous models, Poly Skin-Wax is self releasing
and, therefore, no release agent is needed. Make a small test mold
on a surface identical to the model to determine that release prop-
erties and hardening of Skin-Wax is suitable.
PROCEDURE: Use a therapeutic paraffin bath, available from
medical supply stores, to melt Poly Skin-Wax. A crock pot can be
used to melt Skin-Wax; however, extreme caution must be exer-
cised to ensure that the wax is not overheated. To melt Poly Skin-
Wax, heat to 160-180°F. Skin-Wax must be cooled to 125-135°F
before contact with skin! Even this temperature may cause dis-
comfort in some individuals. Do not use Skin-Wax on sensitive
areas such as the face. The wax must be just hot enough to pro-
duce good results; a few degrees hotter can cause considerable
discomfort. Test judiciously on small areas.
Stir Skin-Wax often during melting and use since temperature
variations in an unstirred bath can result in solidified wax in one
area of the bath while another area heats enough to cause burns.
Monitor temperature in several places in the bath (i.e., near walls,
center and at several depths). Use an accurate thermometer.
Apply Skin-Wax by dipping the model, brushing on or slowly
Speciality Materials 5
FEATURES
• Safe for skin contact
• One-part mold making compound
• No mixing -- simply melt and use
• Fast -- make a mold in 5 to 10 minutes
• Easily repaired with a dab of warm wax
• Flexible when warm
• Self releasing from most surfaces
• Reusable
SAFETY: Before use, read product labels and Material Safety
Safety Sheets. Follow safety precautions and directions. Do not
heat with open flame. Do not heat above 280°F since vapors can
ignite. Use with adequate ventilation. Do not use in the presence
of sparks or open flame. Exercise extreme caution when applying
Poly Skin-Wax to the skin. While Poly Skin-Wax is safe for skin
contact, it is not recommended that repeated castings be made
over a short period as the hot wax tends to remove skin oils and
can cause irritation. For skin applications, avoid reusing wax that
may have absorbed irritating substances from casting materials.
STORAGE LIFE: At least 12 months from date of shipment.
PACKAGING
Poly Skin-Wax is available in 5-lb blocks

Speciality
Materials
pouring over the model surface. For rapid cooling, immerse the
wax-coated model in cool water between coats. Skin-Wax can be
reinforced by laying fabric such as cheese cloth onto the previous
coat and then applying wax to saturate the fabric.
Although some flexibility remains in Poly Skin-Wax at room tem-
perature, if flexibility is needed to remove the model, it is best to
remove it as soon as the wax cools into the elastic (temporarily
deformable) state. For model shapes that do not allow removal
with the mold intact, the mold may be carefully cut and later
rejoined using a warm metal spatula or by “welding” with molten
wax. Small air vents punctured in the mold using a pin or wire
may help release the mold from the model; for example, in cast- The hand is dipped into melted Poly
ing a hand, pinholes at the end of each finger facilitate removal of Skin-Wax (125°F) then into cold water to
the hand. Holes can be sealed later with a dab of molten wax. harden the wax. Over the next few min-
utes the process is repeated 2 or 3
times to buildup mold thickness. After
PHYSICAL PROPERTIES the wax is hardened, the mold is slipped
Softening Temperature 125°F off the hand and is ready for casting.
Plaster, cement, rubber or plastic can be
Use Temperature 125-180°F poured into the hand mold. Be careful
Viscosity @ 180°F 190 cP not to use a casting material that gener-
Specific Volume (in /lb)
3
@ 77°F 31 ates significant heat upon cure. The wax is removed from the
casting and can be melted for reuse. That casting is detailed --
@ 180°F 34
fingerprints and all!

59
www.polytek.com
 5 Speciality Materials
®
Hydrogel N Mold Compound
®
DESCRIPTION: Hydrogel N is a white powder that after mix-
FEATURES
ing with water cures in about 5 minutes to a moist, rubbery mate-
rial. Use Hydrogel N to make quick, single-use molds, especially • Non-toxic-- Safe for body casts
when skin contact is required. Plaster, wax, and certain EasyFlo • Easy to use: just add water and mix
Plastics can be cast into Hydrogel N molds. • Good reproduction of fine detail
MODEL PREPARATION: Hydrogel N can be poured on most • Early strength for fast demold
surfaces with minimal preparation, but perform a small test cure • Variable working time
to be sure that Hydrogel N releases cleanly and does not damage • Low cost
water sensitive surfaces. Use a thin coat of petroleum jelly or Pol-
®
Ease 2300 Release Agent to seal questionable surfaces.
Hands up and on
MIXING AND CURING: Weigh or measure proper amounts of the table! With the
Hydrogel N powder and room temperature water. The mix ratio is use of Hydrogel®N,
3 parts water to 1 part Hydrogel N, by weight, or approximately 1 these children each
water to 1¼ Hydrogel N, by volume. Mix together rapidly to a made a plaster cast
creamy consistency, but avoid whipping in air. For best results, of their own hand at
use a Turbo Mixer (see p. 62) on a variable speed drill. Add pow- a Vacation Bible
der or water as needed to thicken or thin the mix. Working time is School craft ses-
about 5 minutes, but can be extended using Retarder Solution (see sion. Molds for 35
hands were made in
table below). Apply the creamy mix to the model surface with a
less than 2 hours!
flowing motion, pushing air ahead of the mix. Demold with care
2 to 3 minutes after the mix has gelled. plaster shell is set, remove the Hydrogel N mold/plaster shell. For
To make a large blanket mold, make and apply a series of mixes best dimensional stability, make a positive casting immediately.
within 5 minutes of one another. Hydrogel N bonds to itself if the USING THE MOLD: Plaster or waxes below 212°F may be
previous mix is not completely gelled. To help a new mix bond to poured in Hydrogel N molds. For best results use the mold when
already gelled Hydrogel N, wipe the gelled material with a satu- it is as fresh as possible, since Hydrogel N molds shrink as they
rated solution of water and baking soda (sodium bicarbonate). dry. Molds can be kept useable in plastic bags or sealed contain-
Add food color to the bonding solution so that you know where it ers for up to a few days. Molds should then be discarded
has been applied. Continue layering Hydrogel N as needed to SAFETY: Before use, read product label and Material Safety
Speciality
Materials

make a ~3/8-inch-thick blanket mold. In the final layer of wet
Hydrogel N, press “teased” cotton (cotton rolls, available at any
pharmacy) evenly over the entire mold surface and allow to gel.
Remove excess cotton by pulling gently, leaving a thin layer of
exposed fibers. As soon as Hydrogel N is firm, mix and apply a
plaster mold shell using bandages, cheesecloth, or hemp embed-
ded in the plaster. The exposed cotton fibers in the mold will bond
to the plaster shell helping to keep the mold attached. When the
Data Sheet. Follow safety precautions and directions. Handle
Hydrogel N carefully to avoid dust generation. Wear a dust mask.
Avoid eye contact. Hydrogel N is not for human consumption or
use against mucous membranes. Keep skin contact as brief as pos-
sible. Prior to placing Hydrogel N on hair, hair should be slicked
down with petroleum jelly or cholesterol hair conditioning cream.
STORAGE LIFE: At least six months in unopened containers.

LIQUID RETARDER (OPTIONAL)

% Retarder Approximate
in Water Working Time
0 5 min
3 7 min
6 8 min
9 10 min

PACKAGING
Product Volume
®
Hydrogel N 1 qt
Hiram Ball, of Ball Consulting Ltd., demonstrates making a live- 1 gal
body mold using Hydrogel® N. The safe-for-skin-contact alginate 5 gal
yields excellent mold impressions if wax or plaster is cast right Retarder Solution 1 qt
after demolding.

60
(610)559-8620 • (800)858-5990
 Accessories 6
MATERIALS RELEASE AGENTS
HEMP - Long, natural POL-EASE® MOLD RINSE - Liquid concentrate POL-EASE® 2300 RELEASE
fiber that has been the reduces surface air bubbles on plaster castings AGENT - A blend of silicone oils
traditional reinforcement made in Polytek rubber molds. Dip or spray and resins in a convenient aerosol
for plaster mother molds. mold with 1 part Pol-Ease Mold Rinse diluted spray. Pol-Ease® 2300 is an
Available in convenient with 10 parts water. Molds should be wet effective release for use with most
10-lb bundles or when plaster is poured. 5 gal (40 lb) Polytek products. Use a soft brush
economical ~40-lb bales. to distribute evenly.
POL-EASE® MOLD DRESSING - Protects and
12-oz can or Case of 12 cans
POLY FIBER II - Add to rejuvenates Poly Rubber molds that have been
liquid rubbers to thicken exposed to harsh conditions created by the use POL-EASE® 2500 RELEASE
for brush-on application of solvents and petroleum oils contained in AGENT - An aerosol spray release
or plastics for mold certain form releases and casting resins. 5 gal agent that can be easily washed
shells or layup castings. (40 lb) or 55 gal (450 lb). off cast parts for easy finishing.
Add to resin (up to 5% Spray a thin mist over mold
POLYCOLORS - NEW! Dyes for coloring
total weight) to produce surface, then brush gently for
Polytek’s polyurethane
thin gels to thick pastes. uniform coverage.
rubbers and plastics.
(5-gal pail or 10 lb bag) 12-oz can or Case of 12 cans
Available in red, blue,
green, yellow, brown and POL-EASE® 2350 RELEASE AGENT - Mineral
TIETEX® FABRIC -
black. 0.25-lb bottle or 1.0-lb bottle. spirits solution for use with RTV liquid silicone
Strong, conformable
rubbers. Can be brushed or sprayed. Use of a
reinforcing fabric that UV ADDITIVE - For Improved Exterior
soft brush to spread the release agent evenly to
wets out very well. Exposure - Thoroughly stir this liquid additive
improve results. 1 qt (1.5 lb) or 5 gal (26 lb)
Small pieces can be into polyurethane liquid rubber to improve
laminated in at the top exterior durability; greatly reducing POL-EASE® 2450 RELEASE AGENT - A fast drying,
of a seam in brushed or characteristic surface degradation caused by silicone-based release, which can be brushed or
sprayed molds to sunlight or other UV light sources. Add 0.5% sprayed. Flammable! 1 qt (1.5 lb) or 5 gal (30 lb)
prevent tearing. A sheet of the total weight of liquid mix prior to curing.
POL-EASE® 2601 RELEASE AGENT - Water-based
can be laid into the back of an open poured 4-oz bottle or 1-pint bottle (1 lb).
emulsion of silicone oils and resins. Spray
mold to increase durability. Use as bridging POTTERS SOAP - Use to seal plaster models. with the Sure Shot Mini Atomizer for an
material for spanning undercuts in sprayed or Plaster should be damp when soaped. economical alternative to aerosol release
brushed molds. Available as a concentrate from Crystal Inc, agents. After spraying, distribute evenly with a
10-ft sheet (40-in wide) Philadelphia, PA, (215) 368-1661. soft brush. 1 qt, 5 gal (40 lb) or 55 gal (450 lb)
324-ft roll (40-in wide)
POL-EASE® 2650 RELEASE AGENT - A high
FIBERGLASS MAT - Non-woven, 1.5 oz per sq. performance, silicone-free, release agent for use
ft., chopped strand mat for reinforcing Polytek in polyurethane molds when casting concrete or
resins. 3 square yards plaster. 1 qt (1.5 lb) or 5 gal (35 lb)
POLYPLASTICENE - Non-hardening, sulfur-free
ADHESIVES POLY PVA SOLUTION - Water soluble coating
modeling clay. Non-toxic and odorless, with a for use as a barrier coat on certain rubber
smooth, firm consistency for sculpting. Also POLYPOXY® QUICK STICK molds (i.e, Poly-Fast 72-40) to allow resins to

makes great reusable caulk for mold boxes.
1-lb block or 50-lb box.
FUMED SILICA/CAB-O-SIL® - Add to mixed
liquid rubbers and plastics to make thicker and
thixotropic mixes for brush-on application.
5-gal pail
10-lb bag
Cab-O-Sil is a registered trademark of the Cabot
Corp., Tuscola, IL
BRONZE POWDER - Use with unfilled resins
for "cold-cast bronze." One part bronze
powder to one part EasyFlo (by volume)
makes beautiful castings!
2-lb can
10-lb can
110-lb can
ADHESIVE - Two-part epoxy
adhesive with a 1:1 mix ratio
by weight or volume. Bonds
quickly to most clean, dry
surfaces. Sets in 3-5 minutes.
2-lb kit
POLYBOND™ - A polyurethane adhesive that’s
great for repairing torn molds. PolyBond has
1A:3B mix ratio (by weight), a ~3 minute
working time and a ~15 minute cure.
2-lb kit
EPOXYBOND™ - A low viscosity, epoxy
adhesive, which deeply penetrates porous
surfaces creating an excellent bond. It has an
easy 1A:1B mix ratio (by volume), a long
working time (120 min.), and overnight cure.
2-lb kit
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cure without sticky surfaces. While Poly 74,
70 and 71 Series molds do not cause sticky
surfaces on resin castings, PVA may be used
as a barrier coat to prevent resin attack on the
mold. Can be used as a removable sealer for
porous surfaces alone or in conjunction with
paste wax. The green film of PVA washes off
with water. (Specify Clear or Green) 1 qt (2.0
lb) or 5 gal (35 lb)
POLYCOAT - A semi-permanent sealer and
release agent that can be sprayed or brushed
onto a model when using liquid polyurethanes.
In most cases no additional release is needed to
demold the polyurethane rubber. 1 qt or 1 gal
SURE SHOT MINI ATOMIZER -Use with Pol-
Ease® 2601, 2350 and 2450 Release Agents.
Mini Atomizer (7-oz capacity)

61
www.polytek.com
 6 Accessories

MIXING EQUIPMENT BRUSHES SAFETY

POLY PADDLE - ACID BRUSHES - Tin- NITRILE GLOVES -
The 16-inch handle, disposable ½-inch Disposable, powder-free, 4-
Poly Paddle wide brushes with 100% mil nitrile gloves offer
allows complete horsehair bristles. comfort, dexterity and a
mixing of material by thoroughly scraping the Excellent for making small broad range of chemical
sides and bottom of rounded or straight sided brush-on molds. Bundle of resistance. These gloves
mixing containers. 30 or Box of 1 gross (144) offer protection against intermittent contact
SPATULAS - with nearly all Polytek products. Contain no
CHINA BRISTLE BRUSHES natural rubber proteins. 100 per box, Size L
Top quality, all - Wooden handle chip
purpose spatula brushes. 100% China SAFETY GLASSES - With a
with a Bristle available in 1- sleek wrap-around
comfortable, inch and 2- inch width. polycarbonate lens, Uvex
cushion-grip, Use to apply brush-on Bandido® safety glass
vinyl handle is unbreakable, and heat and molds or release agent. 1-in Brush, bundle of offers excellent eye protection, comfort and
chemical resistant. The stainless steel blade is 10; or 2-in Brush, bundle of 10 sporty styling. Meets ANSI Z87.1-1989
semi-flexible for durability and easy mixing. Standard. Made in USA. 1 pair (one size)
The mirror finish wipes clean easily. Available
in two sizes for most small mixing needs. MOLD BOX PROTECTIVE COVERALL -
Kappler NexGen™ coveralls
4-in Blade Spatula
6-in Blade Spatula are made of a micro-porous
MOLD BOX -
fabric that is aerosol and
JIFFY MIXERS - Adjustable to any
liquid proof. Disposable,
Heavy-duty, size up to 24-in x
but durable enough to be
efficient, 24-in x 6-in. The
reworn. Large size and
commercial base is smooth,
light weight allows
mixer, specially plastic faced
mobility. The perfect
designed for particle board. This mold box provides a quick
cover-up for quick, dirty
tough-to-mix, viscous materials. Mixes way to pour a rubber mold. (C-clamps not
jobs. Coverall, Size L
quickly and thoroughly without splashing or included.)
whipping air into the mix. The patented SOLVENT DISPENSING CAN
protective-ring design prevents puncture or MOLD-KEY KNIFE - Plunger can for
dispensing flammable
damage to the mixing container. Made entirely
of stainless steel 304 for maximum durability. MOLD-KEY KNIFE liquid features brass flame
Jiffy mixers fit all ¼- to ¾-inch chucked - NEW! Use this arrestor screens and pump
power tools. Tools with 450-700 rpm give the unique notched assembly. Simply press a
best mixing results. knife to cut cloth or wiper on the
Jiffy Mixer, 1 gal tongue-and-groove plunger to moisten. Two-quart capacity.
Jiffy Mixer, 5 gal seams in molds.
Makes proper Although we don’t offer a full line of
TURBO MIXERS -
Ingenious, mold registration easy. safety supplies, we’ll help you get what
patented, high you need to work safely! Call Polytek and
Accessories

ask for our safety specialist.

efficiency
mixers fit any
power drill with
½-inch chuck and mix more efficiently than a
Jiffy Mixer. Must be kept free of built up
material. It’s worth the price!
Turbo Mixer, ½-gal
Turbo Mixer, 1-2 gal
Turbo Mixer, 3-10 gal
Turbo Mixer, 11-55 gal
TONGUE DEPRESSORS - Made
of straight-grained white birch
for consistent quality.
Convenient, low cost mixing
tools for test cures or small
quantity mixes.
6-in length, box of 500
BANDS & STRAPS
RUBBER BANDS - Top PAILS/OPENER
quality ¾-inch wide
rubber bands made of PAILS FOR MIXING - High density
long lasting, heavy duty polyethylene pails with handles, both 1-gal
natural rubber. Secures and 5-gal sizes are now available in cartons.
mold shell pieces These are the same pails that Polytek uses for
firmly together. 4-in its products. They are excellent for mixing
Bands, 1-lb box 8-in Bands, 1-lb box Parts A & B and often the cured residue can be
stripped out, leaving a clean pail ready for
NYLON MESH MOLD
STRAPS - One-inch wide reuse. Lids can be ordered separately.
1-gal Pails (Box of 10)
nylon straps are
adjustable to 8 ft in 5-gal Pails (Box of 5)
length. They tighten as PAIL OPENER - “Pail Pal” pail opener designed
the buckle locks to to open and close most plastic pails with ease.
ensure a snug fit. Sold singly or bag of 12 Constructed of rugged cast aluminum.

62
(610)559-8620 • (800)858-5990

SCALES
OHAUS CS-2000 PORTABLE SCALE - The ideal
scale for users who need a
scale in a variety of
locations during the work
day. Battery operated with
an automatic shut-off
switch. The CS-2000 has a
capacity of 2000 grams (~5
lb) and readability to 1
gram. The digital display reads in grams or
pounds and ounces. The scale offers simple
operation with a full capacity tare. The CS-
2000 has an easy-to-clean weighing surface.
The AC adapter is sold separately.
OHAUS ES50R ELECTRONIC BENCH SCALE -
This all-purpose,
rugged bench scale
is equipped with a
large, stainless steel
weighing pan to
withstand heavy
industrial use. The
ES50R has a 110-lb capacity, a digital display
readable to 0.05 lb and a full capacity tare.
Can be used with the AC adapter (included) or
batteries for portability. An automatic shut-off
circuit extends battery life.
OHAUS 760-00 TRIPLE-BEAM BALANCE -
Quality, mecha-
nical balance
with readability
to 0.1 gram and
weighing
capacity to 2610
grams (5+ lb) makes this balance more than
adequate for weighing small quantities.
Weight set included.
OTHER ACCESSORIES
POLY PURGE™ DRY GAS
BLANKET - Blast Poly
Purge™ into an open
container just before
resealing the lid to displace
moist air and extend the life
of polyurethane liquids. Poly
Purge™ is heavier than air
and is non-flammable and
non-ozone depleting. It is packaged in an
aerosol can with a special nozzle extension
useful for directing the gas into the desired
space. 10-oz can or Case of 12 cans
www.polytek.com
Accessories 6
DVDS/VIDEOS BOOKS
Polytek offers DVDs and video tapes to help METHODS FOR
customers better understand mold making MODERN SCULPTORS
materials and processes. By Ronald D. Young
POLYTEK MOLDMAKING DVD & Robert A. Fennell
Watch step-by-step demonstrations showing Published in 1980, this
how to make a is still one of the best
poured block mold; general texts on the
brushed blanket mold subject, including a
with plastic shell; very good chapter on
and a poured blanket mold making. (292 pp)
mold with a plastic
shell. See how to use
Polytek polyurethane
and silicone rubbers
and plastics. Only
$5.95!
POLYTEK BODY CASTING AND SPECIAL
EFFECTS SEMINAR/WORKSHOP POLYTEK CURED SAMPLE STRIPS
Body & Face Casting with Hydrogel® Two pages of cured sample strips of most
Alginate, 115 min. Polytek rubbers and resins in a 3-ring binder.
A handy reference when selecting a material
BALL CONSULTING LTD.
for a particular job.
MOLD MAKING AND CASTING
A practical how-to video showing the making
of a poured mold, a brush-on mold and a ROTATIONAL CASTING
poured blanket mold. Casting of Forton® MG
with a metal powder filled face mix and a Rotational casting involves rotating a closed
glass fiber reinforce back-up. Covers patinas mold while a liquid casting material flows over
and other finishing techniques. Use of Forton® the inner surface of the mold. The liquid clings
MG to spray-up a large, rigid column mold to the mold surface just enough to create a thin
and rigid carrier molds also shown. Approx. layer of cured material, which creates a hollow
40-min. casting. Rotational casting is an efficient
method of creating large, lightweight pieces
SUCCESS WITH FULL BODY MOLDS AND
such as mannequins and figurines. Fast-setting
FORTON® CASTINGS
liquids are used so that pieces can be produced
The definitive video on full-body molding. with short cycle times.
This Mark Prent video also includes useful
The 2 machines pictured below are at our PA
information on casting with Forton® MG.
Accessories
facility and are available for demos and test runs.
Approx. 70 min.
BETTER ONE-PIECE HEAD MOLDS FROM LIFE
Master sculptor Mark Prent takes you step-by-
step through every detail of using alginate
mold compounds to make head molds of live
models (i.e., Hydrogel® N). Approx. 75 min.
THE USER’S GUIDE TO REDUCIT®
RUBBER MOLDS, AND INNOVATIVE PLASTIC
SUPPORT STRUCTURES Small machines cost
Mark Prent uses Polytek Mold Rubbers and ~$5,000 and can support
alginate compounds to reduce a life size mold loads of ~ 200 lb.
sculpture to ¼-scale in two steps. This video Table-top versions are
offers the solution to an age old problem while available. Large
maintaining every detail of the original. machines can carry
Approx. 60 min. many molds and cost ~
$12,000.
63
 6 Accessories

DRUM HANDLING PRODUCTS POLYGEL® SPRAYER

Polytek offers numerous products to make Oil-Gate Valve
handling drums easier and safer. A few items for 2-inch Bung
are shown below. Call Polytek for pricing and
details.

Drum Bung
Wrench,
Standard Bronze
Drierite Meters, mixes and sprays select Polygel®
Cartridge rubbers and plastics. Makes superior quality
molds and shells much faster than hand
application using self thickening Polygel®
Drum Deheader rubbers and plastics.

METER MIX EQUIPMENT

DRYING CARTRIDGE PROTECTS PRODUCT Meter mix and dispensing equipment
INTEGRITY - Drums of Polyurethane products automatically measures, mixes, pumps or
Drum Cradle
(both Parts A & B) benefit from use of Drierite sprays Polytek liquid rubbers and plastics. For
Dessicant Cartridges. The cartridge is screwed recommendations on this type of equipment,
into the small bung with an adapter so that air call Polytek Customer Service at 800-858-5990.
entering the drum during dispensing is dry.
Protects product integrity. Drierite Cartridges
have a window to view color change to PORTABLE SPRAY SYSTEMS
determine when cartridge is spent.
Drum Hand Drierite Cartridge and Adapter sold separately. Certain Polytek polyurethane and silicone
Truck liquid mold rubbers and plastics ( e.g.,
Poly 74-55 drum Polygel ® rubbers & plastics, accelerated
unit ready for 1512X polyurethane plastic & TinSil® Spray
use with valve, 25) can be inexpensively meter mixed and
cradle and sprayed using sprayer assemblies and
Drierite accessories from Plas-Pak Industries. Two gun
cartridge. assemblies are available - a 1:1 mix system for
polyurethane rubbers and plastics and a 1:10
sprayer for TinSil® Spray 25. Both sprayers
are available from Polytek and come equipped
Hand Truck with a pressure regulator kit and a
Mixer/Spray Gun Assembly. You need to
Accessories

supply the air compressor. Empty cartridge

Pallet Truck
For larger volume applications, Polytek
products can be purchased in totes. Polytek also
offers accessories for handling and dispensing
products from totes. Call Polytek for details.
assemblies (one tube for Part A and one for
Part B are molded into one piece for
convenience) and static mixers are sold
separately. Cartridge assemblies may be
reused when handled carefully or disposed if
cleanup is impractical. Static mixers are
disposable and should not be reused.
With this handy spray system you can
complete a mold in a one-application session.
For recommendations on this type of
equipment, call Polytek Customer Service at
800-858-5990.

64
(610)559-8620 • (800)858-5990
 Accessories 6
TRIAL UNIT ORDER POLICY GLOSSARY
See for yourself! Try Our Introductory Offer. Blanket Mold: A thin blanket-like rubber
mold, usually ¼- to ½-inch thick. A rigid
To encourage you to evaluate our products, Polytek will ship you the trial unit(s)
shell (mother mold) is required to hold
freight paid (except for hazardous material fees, if any) in the contiguous 48 the floppy blanket mold in perfect shape.
States at special low prices. Only one trial unit shipment of each product per Chasing: The process of cleaning
customer. Subsequent orders are at list price. Directions and MSDSs are sent with unwanted material (flashing) from a
trial units. All trial unit orders must be prepaid. casting.
Freight is free for accessories shipped with a trial unit, up to the value of the trial Flashing: 1. Unwanted fin-like
unit. Call for details. projections of casting materials that have
flowed into mold vents and parting lines.
2. Thin aluminum sheet used to divide
mold sections.
TRY YOUR LOCAL DISTRIBUTOR FIRST Inhibition: Failure of a compound to
cure against a surface within the
Polytek has stocking distributors worldwide; more every day. Call Polytek to learn recommended cure time. The surface in
the name and location of the distributor in your area. contact with the pattern remains gummy
or uncured. Inhibition is most likely to
occur in addition-cure (PlatSil®) silicone
NOTES & POLICIES systems.
Keys: Tongue-and-groove, or button-like
Prices are per unit, including both A & B. (Except one-part materials and certain epoxies.) impressions to align mold or shell
sections.
Terms are 1% 10 days, net 30 days for accounts with approved credit.
Orders prepaid with credit card, money order or wire transfer will usually be shipped Mother Mold (Mold Shell): The rigid
shell over a flexible mold that holds the
the next day providing items are in stock.
flexible mold in the desired configuration.
Orders prepaid with check are subject to delayed shipment until the check clears.
Model: The original shape over which a
No COD Shipments. mold is made.
Prices do not include state and local taxes.
Parting Line: The line where sections of
State tax exemption certificate required for PA customers. a mold or mold shell divide.
Prices are subject to change without notice. Release Agent: A coating applied to
Prices are FOB Easton, PA. prevent liquid rubbers and resins from
Freight will be prepaid on shipments valued over $4,000 for delivery in the contiguous sticking to surfaces.
48 States. Resin: A liquid that can be cured to a
Minimum order $40; also applies to trial units. solid plastic.

Accessories
Any single pint size bottle of Silicone Part A is the full 1-lb kit price for that product. RTV: Room temperature vulcanizing.
Any ½-gal size bottle of Silicone Part A is the full gallon-size kit price for that product. Shims: thin strips of material used to
Minimum charge for any small container is $5. form parting lines.
All video and book sales are final. No returns or refunds. Undercuts: A configuration such as an
Returns must be pre-approved and a 20% stocking charge is charged on all returns. overhang between two mated surfaces,
Return Check charge is $25. such as a mold and model, that tends to
prevent them from separating when
pulled apart. Flexible mold materials
allow molds to be made with limited
TRADEMARKS undercuts because the flexible mold
material bends as the part is demolded.
Polytek®, Polygel®, Polypoxy®, Poly-Optic®, Poly-Sil®, FormRub®, Hydrogel®,
PlatSil®, TinSil® and Pol-Ease® are registered trademarks of Polytek Development
Corp., Easton, PA 18042 USA. Registration is pending for EasyFlo, PolyFoam, Poly
LiteCast, EpoxyBond, Poly Purge and PolyBond.
Cab-O-Sil®, Tietex® and Forton® are marks of their respective manufacturers.

65
www.polytek.com
 Liquid Rubbers & Plastics
for Mold Making & Casting
Polyurethane RTV Mold Rubbers . . . . . .32-39
Poly 74, Poly 75 & Poly 77 Series Rubbers
Our Most Popular Mold Rubbers! With hardnesses that range from a soft,
stretchy Shore A~20 to a very firm Shore A~90, these rubbers find innu-
merable uses as tough, long-lasting mold rubbers or for making rubber
parts, forms or stamps. Many of these systems have 1:1 mix ratios and
all are easily mixed by hand or can be machine dispensed because of
their low viscosities and other user-friendly characteristics. These
polyurethane rubbers are designed for casting concrete, plaster, wax, and
resins/foams with the use of appropriate release agents. Poly 74-20 has
been designed for high-volume concrete casting where the highest level
of elasticity and performance is required. Poly 74-30 is ideal for wax
casting in foundry applications. Firmer versions of the 74, 75 and 77
Series rubbers are recommended for casting plaster and concrete as well
and are chosen based on hardness and other specific physical properties
needed depending upon the size, shape and nature of the master being
duplicated or part being cast. Consult Polytek's technical support staff for
assistance in choosing the right rubber for your application!
Polygel® Brushable/Sprayable Rubbers - Patented Polygel mold rub-
bers are 1:1 mix liquids that thicken upon mixing Parts A and B to a
brushable or sprayable viscosity. Polygel 50 can be applied about ¼-inch
thick while Polygel 35 & 40 are thinner for best detail penetration. With
Polygel Spray 35 & 50, you can make a large mold in an afternoon and
cure it overnight.
Poly GlassRub - GlassRub 50 is a clear, pale-blue, glass like rubber for
casting flexible art objects or for cut molds.
Poly-Fast 72-40 Series Rubbers - These fast-setting rubbers (8-hr
demold) can have varied hardnesses by changing mix ratio or adding Part
C. Can be thickened for brush-on molds with Cab-O-Sil® or Part D.
Poly 81 Series Rubbers - High-performance, RTV, elastomers for parts,
tools and molds. Low moisture sensitivity. Hardnesses of D45 and A90.
Casting Plastics/Resins . . . . . . . . . . . . . .46-56
EasyFlo™ Series Plastics - Easy 1:1 by volume mix ratio, odorless,
resins cure to a white or clear plastic in minutes. EasyFlo 60, 95, 120 &
Clear are super low viscosity, fast casting plastics: great for rotocasting
and bubble-free parts. Also used for making cold-cast bonded bronzes.
Poly 15 Series Casting Resins - Filled Poly 15-3 and faster 15-3X are
excellent for casting parts, molds and tools. Poly 15-6, 1511 and 1512X
make strong, lightweight mold shells. Poly 1510, 1511, 1512 and 1512X
are water thin, with a great thermoplastic feel for prototypes. Poly 15-8
is aluminum-filled for applications demanding heat-resistance.
Poly-Optic® 14 Series Crystal Clear Casting Resins - Poly-Optic 1410
and 1411 are non-yellowing, Shore D85 plastics. Poly-Optic1420 must
be heat cured and is buffable. Poly-Optic 14-70 is a clear rubber with a
Shore A70.
Poly Lite Cast - Has a wood-like feel and can be carved, cut, sanded and
drilled.
Poly Plasti-Flex™ - A flexible plastic for decorative trims and castings.
Polygel® Plastic-75 & Polygel® Shell - Easy, 1:1 mix ratio, use these
resins for making mold shells fast.
PolyFoams - Cast these easy (1A:1B) rigid & flexible foams in closed
molds packed to 4-20 lb/ft3 densities to produce parts replicating wood,
terra-cotta, stone, etc. Use in PlatSil or TinSil molds.
See Our Low Cost Trial Unit Order Policy - p. 65
Silicone RTV Mold Rubbers . . . . . . . . . .40-45
TinSil® 70 Series Silicone Rubbers - Many products, from soft A10 to
firm A60 hardness. Best for casting resins and 70-60 is acceptable for
casting low melting metals. Consider TinSil 70 Series systems for best
economy.
PlatSil® 71 & 73 Series Silicone Rubbers - Consider platinum-cured
PlatSil 71 & 73 Series for highest performance. Several easy-to-use, 1:1
mix ratio systems with 4-hour demolds are available.
PlatSil® Gel-10 Silicone Rubber - Translucent, soft silicone for delicate
casting projects and special effects. Use to make simulated skins and
prosthetic appliances that can be applied directly to an actor or for ani-
imatronic effects.
Specialty Molding/Casting Materials . . .57-60
Latex Rubber Products - Poly Latex 60 is a one-part, thickened, natu-
ral latex for brush-on molds that are strong and durable. When thinned
with Poly Latex N, Latex 60 can be sprayed using an inexpensive cup
gun. Poly Latex False Face Compound is a one-part, high strength, cast-
ing rubber for novelty masks, flexible sculpture and animatronics. False
Face can also be used for dipped molds.
Poly Wax 15 and Poly Skin-Wax - Poly Skin-Wax has a very low melt-
ing point with good toughness after cooling for making molds of hands,
feet and delicate objects with limited undercuts. Poly Wax 15 is mineral
filled for casting in most rubber molds to make recarvable models.
Hydrogel®N Mold Compound - Mix this powder with water to make a
rubbery mold in minutes. Yields excellent mold impressions if plaster or
wax is cast right after setting. Safe for body contact.
Epoxy Resins and Curatives - Polypoxy® 1010 is a general-use, low
viscosity, epoxy resin. Mix with Poly Cure 1212 and bronze or other
metal powders for production of cold-cast bonded bronze in rubber
molds. Call for information about other epoxy systems.
Accessories . . . . . . . . . . . . . . . . . . . . . . .61-64
Polytek offers many accessories so you can obtain all your mold-making
supplies from a single source!
Pol-Ease® Release Agents - Aerosol Pol-Ease 2300 & 2500 and water-
based Pol-Ease 2601 allow for easy release of rubbers from models and
resins from molds. Pol-Ease 2650 is best for high volume concrete and
plaster applications.
Poly Adhesives & Bonding Agents - PolyBond™ is a flexible, high per-
formance, polyurethane adhesive for many applications. EpoxyBond™ &
Quick Stick are epoxy systems for similar rigid bonding applications.
PolyFiber, Bronze and Other Fillers
Safety Equipment - Polytek sells gloves, coveralls, solvent cans and
more. Work safe!
Mixers, Scales, Books and Videos & Other Equipment
Our latest training DVD demonstrates various mold making techniques
and is only $5.95! Polytek can suggest rotocast machines and meter-mix
pumps/sprayers to dispense liquid rubbers & plastics to meet your par-
ticular requirements. Please call to let us help!