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Using Alja-SafeŽ Lifecasting Alginate to Cast Silicone Body Parts
What’s Sets Alja-Safe® Apart? In addition to being an exceptional body molding material, Alja-Safe® alginate does not contain free crystalline silica (a known carcinogen).  Not only does this make Alja-Safe® safer to use, it also means that you can cast platinum silicone rubbers directly into finished molds.  Platinum silicones can often bond in other alginates that contain crystalline silica.

Alja-Safe® also captures detail better than other alginates, giving you a more accurate reproduction of your original.  Alja-Safe® is easy to use and cures quickly. It reproduces fine detail and makes and excellent temporary mold – good for one or two reproductions of any body part. 

The sequence shows how to make a perfect reproduction of an entire arm.
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1 - Begin by creating a containment field to hold Alja-Safe® molding gel.
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2 - The plastic tube is taped along the seam line to ensure stability.
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3 - The plastic tube is adhered to a board using clay. Make sure the tube is completely secure - hot melt glue may also be used.
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4 - Alja-Safe® molding gel is a powder that is mixed in equal parts with water.
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5 - Measure out the appropriate amount of water. With 80° F / 27° C water, Alja-Safe® will have a working time of 8 minutes and a demold time of 10 minutes.
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6 - Equal parts by volume of Alja-Safe® and water are ready to be mixed.
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7 - Begin by pouring water into the mixing bucket.
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8 - Alja-Safe® is then added to the water.
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9 - Using a drill powered squirrel mixer to mix Alja-Safe® will ensure a proper and thorough mixture.
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10 - Model's arm is placed inside the tube.
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11 - Alja-Safe® is poured around the model's arm. Be sure the model is not touching the side or bottom of the container or finished mold will turn out deformed.
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12 - Hold that pose: Alja-Safe® will set in about 10 minutes.
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13 - Once Alja-Safe® has set, it is time to remove the model's arm.
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14 - Slowly and careful wiggle the arm free of the alginate. Caution: removing the arm too quickly can cause tearing in the mold.
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15 - Once the arm has been removed, the Alja-Safe® mold is ready to be cast into.
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16 - Platinum silicone rubber is measured. In this case, Ecoflex® 00-30 will be used to make a super soft silicone replica. Ecoflex® is measured in equal parts by volume.
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17 - To give the finished piece some realistic color, Silc-Pig® Fleshtone silicone pigment is added to Part B.
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18 - Thoroughly mix pigment into Part B prior to combining with Part A.
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19 - Combine Parts A and B of silicone rubber.
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20 - Thoroughly mix the silicone rubber until there are no color striations present in the mixture.
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21 - For best results, Ecoflex® 00-30 should be vacuum degassed prior to pouring into the mold. This will help eliminate any bubbles from causing defects in the finished piece.
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22 - Once the rubber has been degassed, it can be poured directly into the Alja-Safe® mold.
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23 - Pour silicone to the top of the mold. Ecoflex® 00-30 has a demold time of about 4 hours.
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24 - Once the rubber has fully cured, the Alja-Safe® mold can be removed. Alginate molds are typically one-time use as they must often be broken apart to removed castings.
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25 - Continue peeling away the Alja-Safe® until the casting can be removed.
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26 - The Alja-Safe® in combination with the silicone rubber has created a perfect reproduction of the model's arm. Detail as small as a fingerprint has been accurately captured.
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27 - Ecoflex® 00-30 is extremely soft and stretchy. It can be twisted, stretched and manipulated in many way without breaking or tearing.
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28 - Effects-driven films like Harry Potter and the Chamber of Secrets use Alja-Safe® and Ecoflex® 00-30 regularly. In this scene, actor Daniel Radcliffe's arm is replaced by a flexible Ecoflex® 00-30 replica.
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29 - Effects-driven films like Harry Potter and the Chamber of Secrets use Alja-Safe® and Ecoflex® 00-30 regularly. In this scene, actor Daniel Radcliffe's arm is replaced by a flexible Ecoflex® 00-30 replica.
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30 - Effects-driven films like Harry Potter and the Chamber of Secrets use Alja-Safe® and Ecoflex® 00-30 regularly. In this scene, actor Daniel Radcliffe's arm is replaced by a flexible Ecoflex® 00-30 replica.
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