How to Made a Fiberglass Mold
Strong and lightweight composite materials, such as fiberglass, have chemically bonded fibers. These characteristics cause fiberglass to be capable of being molded or shaped for a variety of purposes. Fiberglass molds are copies that are made of fiberglass-reinforced plastic. These molds are useful for a variety of home, automobile and craft purposes. They allow the user to create a replica of most items that can be made of fiberglass, such as car bumpers, beads and decorations. Does this Spark an idea?
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Things You'll Need
- Safety goggles
- Chemical resistant gloves
- Plug
- Mold release wax
- Polyvinyl alcohol parting agent
- Spray gun with adjustable pressure or poly foam brush
- Fiberglass
- Gel coat
- Resin
- Wedge or Stick
Instructions
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Purchase or construct a plug as the first step in constructing a mold from fiberglass. A plug is an identical copy of the item that the fiberglass product will be shaped as. In many cases, the item itself serves as the mold. The most common materials to use for plugs are putty, sheet metal, wood and plaster.
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Cover the plug with a mold-release wax. Make sure that the mold-release product is specially formulated for fiberglass-reinforced plastic. Polish each layer before applying the next layer. Apply the layers in alternating directions. Allow one hour for the wax to cure between coats. Apply three to five layers of the product so the plug will release the fiberglass mold easily.
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Use a spray gun to apply a polyvinyl alcohol parting agent product to the plug and any new molds. Apply several thin coats followed by a heavier coat. The pressure of the spray gun can be modified to make the coats thinner or heavier as needed. Alternatively, a poly foam brush can be used to apply the parting agent. Allow the parting agent to dry for at least 30 minutes before moving to the next step.
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Apply the next layer of fiberglass to the surface of the plug. Limit the number of layers applied at one time to three. After the third coat has been laid, allow the fiberglass sufficient time to cool before adding additional layers.
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Use a roller, brush or spray to apply the fiberglass. The first layer to be applied is called the gel coat and this will make the mold more durable.
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Allow this layer to cure, then sand out any imperfections from the material and trim any excess.
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After the fiberglass has been applied, apply a layer of resin over the fiberglass. Use a roller to remove air pockets from the fiberglass and resin layer. Allow the resin time to set and cure. This preliminary curing process will take five days.
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After five days have passed, use a small stick or wedge to separate the fiberglass mold from the plug.
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Allow the fiberglass mold five additional days to cure a second time prior to handling or using it.
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Tips & Warnings
Start making the mold early in the day. This way, the first layer of fiberglass can be placed in the mold by the afternoon.
Use caution while working with flammable materials.
Wear chemical resistant gloves.
Wear safety goggles.
Keep materials away from children.
Use in well-ventilated area.
Follow the manufacturer's safety instructions.
References
Resources
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