Hi. I’m making shin guards for some soccer players and iam having a few problems backing the molds. I am using expanding foam and sometimes expands too much. What kinda material can i use instead of foam?
Here’s a pic
https://cld.pt/dl/download/9461bca0-8162-4c30-ba6a-66bd1ade49c4/20140816_153934.jpg
You need to make a proper mold out of fiberglass if you want a nice carbon part to be made. To recreate all of the contours you will need to use vacuum bagging or infusion. Without vacuum you all need to do fixes because it may not recreate the shin guards perfectly. For vacuum to be used, you will need a strong mold. Here is a tutorial/video of how to make a fiberglass mold:
http://www.fibreglast.com/fibreglast_how_to_make_fiberglass_mold
Just to point out, you can make a part without vacuum, but you may need to fix errors because the laminate will not be pushed down into the mold like it would if you used vacuum in the process.
Hi Wildcard thank you for your reply, i can’t use fiberglass. My shin guard are personal and not standard, that’s why I’m using plaster 
Anymore idea? Please…
Why don’t u use more plaster ? More plaster is tronger
i dont see why they need to be ‘backed’ ?
if the fiberglass is 4-5mm thick it will be more than strong enough, id put a bridge piece to stop the piece from curling
Michiel I can’t because will had more thickness, its stronger but not enough.
Blackrat its plaster not fibreglass.
Enviado do meu Nexus 7 através de Tapatalk
Aaah okay
Well stop messing about with the plaster and use fiber glass ? Wrap the persons leg with three or four layers of plastic and layup some glass onto his legs 