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.