|Dreams To Reality Studios (Norristown, PA) does production resin casting for a number of clients around the U.S. and Canada, and is always looking for innovative ways to reduce costs and save time. One technique that DTR uses involves Ease Release® 200, which continues to be our best seller for rapid prototyping and casting.
The Specifics - DTR Studios recently secured a job to produce a few hundred model horses using a fast set polyurethane resin.
The horse model was sculpted in clay and molds made using silicone rubber. Prior to casting the resin, Ease Release® 200 is applied to the mold followed by a powder coating of ATH (aluminum trihydrate).
An air hose is used to blow any excess powder from the mold. The urethane resin is then cast into the mold and demolded in about 10 minutes.
The casting comes out of the mold perfectly dry with a matte finish, and shipped to another location for painting. An auto body primer is applied, followed by an acrylic paint and finally an acrylic sealer. The major advantage to powder coating is that there is no release agent to remove when the casting comes out of the mold. Models can be immediately primed and painted.
DTR President, Michael Kryger, selected the Ease Release® 200 for two reasons: 1) applying the release agent to the silicone mold resulted in longer mold life and 2) the Ease Release® 200 does not go on heavily and is readily absorbed by the ATH powder.
The labor and time savings realized by employing this technique is significant.
Mann Ease Release® 200 is sprayed on mold.
Aluminum trihydrate (ATH) is brushed onto the surface of the mold.
Excess powder is blown away.
Castings have a paint ready finish.