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Using Alja-Safe® 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.
 Begin by creating a containment field to hold Alja-Safe® molding gel.

1 - Begin by creating a containment field to hold Alja-Safe® molding gel.
 The plastic tube is taped along the seam line to ensure stability.

2 - The plastic tube is taped along the seam line to ensure stability.
 The plastic tube is adhered to a board using clay.  Make sure the tube is completely secure - hot melt glue may also be used.

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.
 Alja-Safe® molding gel is a powder that is mixed in equal parts with water.

4 - Alja-Safe® molding gel is a powder that is mixed in equal parts with water.
 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.

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.
 Equal parts by volume of Alja-Safe® and water are ready to be mixed.

6 - Equal parts by volume of Alja-Safe® and water are ready to be mixed.
 Begin by pouring water into the mixing bucket.

7 - Begin by pouring water into the mixing bucket.
 Alja-Safe® is then added to the water.

8 - Alja-Safe® is then added to the water.
 Using a drill powered turbine mixer to mix Alja-Safe® will ensure a proper and thorough mixture.

9 - Using a drill powered turbine mixer to mix Alja-Safe® will ensure a proper and thorough mixture.
 Model's arm is placed inside the tube.

10 - Model's arm is placed inside the tube.
 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.

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.
 Hold that pose: Alja-Safe® will set in about 10 minutes.

12 - Hold that pose: Alja-Safe® will set in about 10 minutes.
 Once Alja-Safe® has set, it is time to remove the model's arm.

13 - Once Alja-Safe® has set, it is time to remove the model's arm.
 Slowly and careful wiggle the arm free of the alginate.  Caution: removing the arm too quickly can cause tearing in the mold.

14 - Slowly and careful wiggle the arm free of the alginate. Caution: removing the arm too quickly can cause tearing in the mold.
 Once the arm has been removed, the Alja-Safe® mold is ready to be cast into.

15 - Once the arm has been removed, the Alja-Safe® mold is ready to be cast into.
 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.

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.
 To give the finished piece some realistic color, Silc-Pig® Fleshtone silicone pigment is added to Part B.

17 - To give the finished piece some realistic color, Silc-Pig® Fleshtone silicone pigment is added to Part B.
 Thoroughly mix pigment into Part B prior to combining with Part A.

18 - Thoroughly mix pigment into Part B prior to combining with Part A.
 Combine Parts A and B of silicone rubber.

19 - Combine Parts A and B of silicone rubber.
 Thoroughly mix the silicone rubber until there are no color striations present in the mixture.

20 - Thoroughly mix the silicone rubber until there are no color striations present in the mixture.
 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.

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.
 Once the rubber has been degassed, it can be poured directly into the Alja-Safe® mold.

22 - Once the rubber has been degassed, it can be poured directly into the Alja-Safe® mold.
 Pour silicone to the top of the mold.  Ecoflex® 00-30 has a demold time of about 4 hours.

23 - Pour silicone to the top of the mold. Ecoflex® 00-30 has a demold time of about 4 hours.
 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.

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.
 Continue peeling away the Alja-Safe® until the casting can be removed.

25 - Continue peeling away the Alja-Safe® until the casting can be removed.
 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.

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.
 Ecoflex® 00-30 is extremely soft and stretchy.  It can be twisted, stretched and manipulated in many way without breaking or tearing.

27 - Ecoflex® 00-30 is extremely soft and stretchy. It can be twisted, stretched and manipulated in many way without breaking or tearing.
 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.

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.
 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.

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.
 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.

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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