Moulding and Resin Casting Workshop

by Jason Miller

Text and photos by Dominic Newland, Edited by Jason Miller

First published in the August 2009 AMMS Brisbane newsletter

At the April AMMS meeting Jason gave an excellent demonstration of making moulds and resin casting, explaining to the eager crowd about many of his hard learned techniques and the pitfalls to avoid.

At the demonstration Jason made a one piece mould with a pouring plug, and showed how to pour resin into this and other types of moulds

Safety: Polyurethane resin can be a dangerous product to use.

Note: All silicone referred to in this article is "Pinkysil". An addition cure silicone rubber from Barnes Pty Ltd. It is a very fast cure rubber, which has a pot life of about 5-6 minutes after mixing.

Creating a One Piece Mould for "Drop Casting" or "Home Casting"

This is good for simple parts that don’t have large undercuts. It also involves creating a pouring plug that leaves a small casting block that needs to be removed from the resin replica that is created. The example here is a 1/35 Panther road wheel.

Resin Pouring into a One Piece Mould (with and without a pouring plug)

Always have eye protection when handling resin, as a slip when handing the mould or the resin can lead to resin being splashed into your face and or eyes. Jason can attest to not being able to see from his left eye for 3 days.

Resin Pouring into a Two Piece Press Mould

Other advice

Easy Cast is the thinnest resin on the market from Barnes Sydney. Jason can order it for AMMS members at cost plus a small $5 fee. Resin can be bought in packs of 500g, 1kg and 2kg of resin (which is a lot of resin). Jason can also make the mould of a part for AMMS members, who can then buy the mould off him to use at home.

Shake your resin bottles occasionally to avoid it settling too much. Any particles in the resin bottles that become mixed in your moulds will gradually leak unmixed resin chemicals out of your cast resin part, ruining it.

You know if your resin has become too old if the mixed resin starts to foam, or if the cured resin starts stays expanded in the mould and is full of bubbles like a honey comb. It should be disposed of when it gets to this point.

Happy casting