Given the health situation that we are going through worldwide, in this Feroca article we want to explain in a few simple steps: how to make a mold and copies to make a production of a super support for acetate of protective masks. This, in order to maximize the protection of both workers from all sectors, and the population in general against the high risk of infections by COVID-19.
In these difficult times that we are all experiencing, we have to do our bit to stop the curve. We teach you to do this so that all of us who have the possibility can contribute to this cause, because together we are stronger and we can do everything.
In the following video you can see the live that we do on how to make the supports of the protection screens with our materials.
For this process, we must follow the following steps:
The first thing we need is an original. In this case the original is a 3D printed model that has been provided by the University of Granada, in which they have worked to comply with all the necessary measures.
We leave you the download link in case you want to collaborate with the initiative.
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Once we have the piece printed in 3D, the first thing we do is cut out a pen cardboard surface larger than the piece. This will be used as a base to work the formwork of the mold.
With more pen cardboard, we make strips about 5 centimeters wide.
Once we have the strip, every 3 or 4 centimeters we make repeated vertical cuts on the strip, which will then allow us to make a curved surface.
Glue the piece to the base with a couple of points with the thermo-sealing silicone or the ultra-fast cyanoacrylate glue.
It is very important to make the formwork watertight, because if it leaks the silicone will come out of the mold out there and it will not go well.
To seal it, with the same thermo-sealing gun we put a thread covering all the joints where we can go the silicone (the base, walls, joints between cardboard pen ...).
The joints can also be sealed with a thin strip of industrial plasticine.
The silicone that we are going to use, as we have mentioned, is the Silastic 3483, which is ideal for this project, since it will provide us with greater ease when removing the pieces from the formwork, due to its low hardness. Being a piece with such fine parts, a more flexible silicone is suitable.
Although we could also use the Silastic 3481, only that, using this, it would cost us a little more to get the pieces out of the mold.
We must also mention, that we can make the silicone mold with any of the 3 optional catalysts. Although, we always recommend the standard 24h for people who are new to the world of molds.
For this visor and with the formwork we have made (shown in the previous images), we have used 700 grams of silicone, with its corresponding 35 grams of catalyst.
We weigh it with a scale and mix well.
Once we have made the mixture, we must pour it over the formwork from a high point 30-40 cm and, in a fine thread so that the bubble breaks.
We try to register the whole piece, so that the mold is as faithful as possible to the original.
To avoid bubbles in the register, you can give a few light blows at the base of the piece and blow on the surface to remove the superficial ones.
Once the silicone is cured, we will proceed with the formwork of the mold.
First we remove the walls.
Then we take off the silicone from the base little by little, taking care not to break the mold or the original.
And ready, we will have our perfect silicone mold to replicate the support of the protective mask.
Well, surely now you are wondering how to create this support for the visor Right? Well, keep reading, because we tell you about it below.
We recommend doing it in a ventilated place such as a terrace or, failing that, a room equipped with an extractor.
It is best to work in a clean and protected area, either with plastics, tablecloths or a few sheets of newspaper.
We also have to pay attention to protecting ourselves. So we will put on gloves and a mask.
First, we need to prepare the Feropur PR55 resin mixture plus Feropur E55. The mixture is very simple, it is in equal parts or 1:1.
For every 100 grams of part A, another 100 grams of part B must be mixed.
Mix the resin and carefully pour it into the mold. With our hands we help ourselves to open the mold well so that the resin filters and enters well in all corners.
Keep in mind that the support has very fine parts and, it is convenient, open the mold a little with your fingers to be able to strain the resin and that it does not overflow.
It is very important to use gloves in this step, since we can stain our hands with resin.
The resin has a very fast curing so this process must be done relatively quickly, between two and three minutes of work.
After 15 minutes you can take your copy out of the mold and make another casting.
It is always advisable to remove possible burrs with a cutter or scalpel.
You have to keep in mind that this particular piece is going to go over the head, so you have to cut and sand everything that can puncture.
As you will see, it is a simple way in which we can collaborate as molding professions in the face of the coronavirus crisis.
All of you who contribute to curbing the spread of coronavirus in any way should be proud.
Since the confinement we can also go further and offer our talent to help the professionals who are giving it all for us.
We hope you will join this initiative and, if you have any doubts, we will be here to clarify it. Together we can save lives! .
Gracias Jorge, te ha quedado mu bonito!
Me ha gustado, estoy intentando hacer una mascarilla pero el primer fallo lo he tenido con el encofrado, se me ha salido la silicona y todo a tomar por saco, estoy haciendo un encofrado en 3D, si, sé que es un trabajo innecesario, pero así me aseguro que no tendré problemas de fuga, otro tema será que lo romperé para sacar el molde.
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At the forefront of materials for molding in Spain for more than 35 years, Feroca continues to innovate, and continuously add products to its catalog, always looking for new and better materials that facilitate the molding and modeling tasks of our customers as much as possible. That is why Feroca seeks partnerships with the key manufacturers of each type of product, which has led us to be a distributor of the most prestigious brands in the sector, among which Polytek, Neill's Materials, Dow Corning, Chavant, Monster Makers and many more.
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