5. Casting Process

Time is key in the Molding or Casting process.  Many of the processes have one chance to be done right. Scheduling out each step helps:

Casting form setup 

 Secure the mold master to the base of the casting form with glue, 2 sided tape, or caulking.

 Seal all seams of the form and the base of the mold master.

 Measure the casting volume  use sand, water or wax to measure the mold / casting volume

 Test the mold form mold for leaks with water.

 Dry the mold form and object

 Apply mold release

Preparing for the unexpected:  leaks, spillage, under pour, over pour, etc.

 Cover surfaces it absorbant brown paper

 Have paper towels ready

 Put on PPE as needed (gloves, masks, face shield, etc.)

Prepare materials before mixing:

 Do the math. 1/2 A, 1/2 B

 Measure each part in a seperate cup.

Setup up the mold / cast tooling

 Cover the casting volume of the mold with mold release. 

 Secure casting form with clamps, bands, weights, and / or  glue.

 set out mixing tools: sticks, mixing blender, scrapers 

 test tooling before mixing.

NO NEW last minute technology. Try new technology on a test piece.


 Set timer for pot life

 Scrape the side and bottom


 Smooth pouring will reduce bubbles. 

 Pour starting in the low point.

 Observe - watch for leaks, spills, until the end of the pot life

Mold storage

 Put the in process work in a safe area where for the cure time

  Set timer for cure time.


 Carefully extract the mold master


 keep "objects" out of the process that aren't helpful. reduce hazards.

 remove spills before material sets when possible.

 Carefully dispose of waste.