There is a learning curve involved in getting good results with SMASH! Plastic breakaway glass. The following tutorial takes you step-by-step through the process of making a large window pane suitable for using as a breakaway glass prop for stage or movie special effects.
You will need the following equipment:
Melamine Particle Board
Super Insant Epoxy
Plexiglass sheet (model)
Acrylic Strips (mold box)
Hot Glue Gun / Glue Sticks
Digital Gram Scale
Mold Max 30 Silicone Rubber
Vacuum Degassing Chamber
Smash! Plastic
1 - Remove protective coating on one side of the plexiglass
2 - Adhere plexiglass to baseboard with super instant epoxy
3 - Place second board on top and apply pressure until epoxy cures
4 - Make sure surface is level
5 - Hot glue base of retaining walls to prevent leaking
6 - Measure and Mix Mold Max 30
7 - Construct retaining walls out of acrylics strips and hot glue
8 - Vacuum Mold Max rubber for 2-3 minutes
9 - Remove protective coating from other side of plexiglass
10 - Pour Mold Max 30 in center of model
11 - Rubber thickness should be 1/8” / 0.32cm. Let Rubber Cure 16 Hours at room temperature (72 F / 23 C)
12 - Peel away from model
13 - Place mold in oven/hotbox for 4 hours at 150F 60C
14 - Place paper down the length of the mold. Purpose: Helps in demolding glass pane
15 - Place mold on paper
16 - Safety: wear safety glasses and NIOSH approved respirator
17 - Mix ratio is 100a: 100b by weight or volume
18 - Dispense equal amounts of parts A and B intro measuring containers
19 - Pour Part A into mixing container
20 - Pour Part B into mixing container
21 - Mix thoroughly for 90 seconds
22 - Pour SMASH plastic into center of mold
23 - Slowly pull paper and mold off table edge while pane is secured
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