Multi Piece Split mold from 3D printed / foam milled combo plug


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Artist416
Artist416
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Greetings All,
I'm making a large Giraffe sculpture that will be outside for 6 months, and therefore need to the final work to be strong as it may be climbed on.
I messaged last month for advice and appreciate the feedback I received. Originally I was planning on coating the plug, but now I believe to keep decent detail, I need to create a mold.

I'm looking for feedback on the feasibility of my current plan:

I'm about 80% done generating a not very strong plug / master model, out of CNC milled pieces and 3D printed peices. 

The idea is to glue these all together and fix all seams with drywall compound (easy to sand), then rub / buff it with a wax mold release, and layup as many pieces for the mold as I will need (I imagine 4-10 seams in the mold).

Then, the idea is to layup poly resin and glass into these mold pieces, trim the extra flashing prior to full cure, and laminate all the pieces together.

-- 
So my process plan is:

plug with drywall for finishing / fairing > wax mold release > gelcoat > complex poly mold layup > mold removal and gell coat / a layup within seperate mold pieces > trim > Assemble > final body filler of seams and last gell coat coating / sanding > painting

Does this sound possible? Is there any important steps I'm missing here?
The next month I'll be heavily invested in this project, so your experience is like gold to me.









oekmont
oekmont
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Is you plan to take a mould of the whole assembly? Because it's almost impossible to take a mould from the legs and body all together. I would make a mould of each leg, and a mould of the body/neck/head, but without ears, tail and horns. Instead I would implement some recesses to glue those parts in. I would reinforce the parts with wood wich I would bond with cotton thickened resin, at the places where body and legs meet. Than I would bolt and bond the legs onto the body.
drywall compound is a horrible surface to take moulds from. Use a thin layer of coating epoxy instead, and sand it smooth. This might take several tries.
I would still recommend to just wrap the foam structure. You probably aren't aware of the difficulties and expenses you will face just to create the moulds. Same for the parts itself. I will be far easier to rework some details on the positive layup.

Artist416
Artist416
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oekmont - 3/31/2019 5:43:42 PM
Is you plan to take a mould of the whole assembly? Because it's almost impossible to take a mould from the legs and body all together. I would make a mould of each leg, and a mould of the body/neck/head, but without ears, tail and horns. Instead I would implement some recesses to glue those parts in. I would reinforce the parts with wood wich I would bond with cotton thickened resin, at the places where body and legs meet. Than I would bolt and bond the legs onto the body.
drywall compound is a horrible surface to take moulds from. Use a thin layer of coating epoxy instead, and sand it smooth. This might take several tries.
I would still recommend to just wrap the foam structure. You probably aren't aware of the difficulties and expenses you will face just to create the moulds. Same for the parts itself. I will be far easier to rework some details on the positive layup.

hey Oekmont, thanks again for the feedback.
I was just re-reading your initial posts from earlier in the month -- really good.

OK I think you're right. I don't know what I'm getting into.. Here's a new plan:
A vendor in Toronto has a bunch of heavily discounted carbon fiber. Ordinarily I couldn't afford it, but it's 70+ % off.
My new thought is to wrap the model in carbon fiber and epoxy, possibly with a metal armature put in during assembly / pre coating.
Does that sound like a reasonable idea to you? What would be the minimum weight / layer combo of carbon to give any kind of strength?
Would a single thin 'veil' type layer of carbon in epoxy do anything?

I did a test last night with some much lower grade materials: lay two layers of 10mil glass veil dipped in some polymer gypsum I had laying around and layed it over some scrap polystyrene (low density white) and the shell was surprisingly decent. If a couple thin layers of carbon could do better than that, I might be good to go?





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