FRP sculpture mould

Producing an FRP sculpture mold is our first step, after which we aim to create and deliver FRP products tailored to the practical needs of people in their daily lives. To begin with, let’s talk about the glass steel sculpture plaster mold. Plaster models are known for their heat resistance, affordability, low thermal conductivity, and excellent replicability. They are typically used to create master molds. These molds are easy to fabricate, making them ideal for large-scale productions. However, they lack durability, are susceptible to damage, and take longer to dry. As a result, they’re most commonly used for single-piece items or intricate designs like embossed pieces. Most plaster used is hemihydrate gypsum, commonly referred to as plaster of Paris. Similar to cement molds, brick bases and wood can serve as the foundational structure before being covered with a plaster layer. To enhance rigidity and prevent cracks, it's suggested to include adequate fillers in the plaster mix. For instance, adding quartz can help reduce shrinkage and cracking, while incorporating cement (with a ratio of 7:3 plaster to cement) can boost strength. Some have also proposed mixing an appropriate amount of latex with plaster, diluting it with water to form a mold that is both strong and resistant to powdering. Plaster molds can act as master molds for low melting point alloy molds, allowing alloys to be cast in a hot state. When creating a sub-mold using a plaster master mold, the surface of the master mold should be coated with a release agent such as potassium soap solution, transformer oil, edible oil, a mixture of 20% stearic acid and 80% kerosene, or even petroleum jelly. Gypsum molds can be repaired using a water pen mixed with plaster powder. The drying process for plaster molds involves heating them to temperatures between (60 to 120) °C for (4 to 5) hours, followed by natural cooling. Once cooled, they can be gently polished with metallographic sandpaper, then baked again at (100 to 150) °C for (8 to 10) hours, and finally at (200 to 230) °C for (20 to 24) hours. Next, there's the FRP sculpture rubber mold, which is generally made from silicone rubber or polyurethane resin. These molds are utilized for complex reliefs, round carvings, and various shapes. However, they aren't used independently; instead, they require other materials like plaster sleeve molds to function properly. They're commonly used for threaded pours or parts that overlap and cannot be directly removed due to their flexibility. This allows the outer mold to be demolded without issues, such as with lion statues, dragon sculptures, or even depictions of bodhisattvas and cartoon characters. This method is particularly useful when the batch size isn't too large. Moving on to paraffin films, these are employed for products that are either limited in number or have complex shapes that are hard to demold. For instance, to create a monolithic elbow, including a 90° elbow, two elbows can serve as a master mold. After filling the 90° cavity with paraffin, the paraffin core can be slightly removed post-demolding. After finishing, FRP is applied to the outer wall, heated, and solidified to melt and flow the paraffin, resulting in a complete FRP product. To decrease shrinkage deformation and increase rigidity, around 5% stearic acid can be added to the paraffin wax. These molds are easy to manufacture, demold, and reuse. However, their precision isn’t always high. Another approach involves immersing a steel pipe in melted paraffin wax at 70-80 °C, lifting it, and repeating the process until the desired thickness is achieved. The surface can then be slightly trimmed before applying FRP. To prevent paraffin cracking, a small amount of butter can be added to the wax. Alternatively, a thin layer of cellophane can be coated on the outside of the wax as a core. After the glass-reinforced plastic is cured, the heated steel tube melts the paraffin, allowing for easy demolding. Concrete molds are frequently used for line-type rules and products with low reusability, such as spiral, wavy, circular, arched, or three-dimensional grooved products. These molds are cost-effective and rigid. Bricks can serve as a foundation, followed by covering with cement mortar, polishing, applying putty, and further polishing and painting. This cement mold can be directly used to produce FRP products or act as a master mold for reverse-engineering FRP molds. Cement molds dry slowly, even under normal conditions, taking over a week to finish surface painting tasks. Wooden molds are primarily used for large products with flat lines. These molds can be directly used as forming dies for FRP products or as transitional masters for reverse-engineered FRP molds. The types of wood used for mold-making include red pine, ginkgo, and fir, with a water content requirement of 15%. The wood should be resistant to shrinking and warping and free of knots. Once the wooden mold is fabricated, it can be coated with a resin (surface putty) and then sanded four times from coarse to fine with water sandpaper. The final sanding uses 800# or 1000# sandpaper, followed by applying polishing paste. The polisher then polishes and waxes the mold, making it ready. It's also possible to paint and cover the wooden mold directly to create a wooden mold. Metal molds, especially steel molds, are typically used for small-sized molded products with large batch sizes. For example, stainless steel plates are used for smooth-surfaced FRP flat plates, while angle steel and channel steel are used for profiled products. Since the molded product is not only pressured but also heated, there are also large products with uncomplicated shapes. Although brass is a common metal, it can be easily affected by resin additives, negatively impacting the curing of the resin. Brass should not be used unless the working surface has been chrome-plated or coated with another metal. Manufacturing and processing metal molds is challenging and expensive. Additionally, the composition of low melting point alloy molds includes Z 99.3%, A 1.4%, Cu 3%, and M 0.5%, with an alloy hardness (HB) of approximately 100 when the temperature is between 50-80 °C. These alloys have good fluidity but poor wear resistance, making them suitable for manufacturing plastic molds with complex shapes and fine patterns, with a usage temperature generally greater than 80 °C. Another low melting point metal consists of 58% bismuth and 42% tin, with a melting point of 135 °C. Low melting point alloy molds offer advantages such as a short molding cycle, a simple process, and reusability.

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