Whats your flanging technique and materials do you use?

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#1

All of my molds I make are made with clay to extend the part to a flat surface. It works well but I would like to start flanging. I tried to play around with thin aluminum but it was very hard to shape to my part. I posted a few weeks back about wax sheets which seems like they might work but they are very expensive so not really worth trying.

What material do you use to make a flange and how do you secure it to your part? I have tried hot glue which works, but then how can you wax the flange and part you want to mold without screwing up the flange you just made?

As always, Thanks!

#2

It really depends on the contour of the flange. I would often mount to a flat board and fill in gaps with filler rather than make a curved flange. On two or 3 part molds I often use MDF with the back of it kerfed to make it flexible. The flanges then get mounted to framework that holds them in the correct shape. The master then get mounted in this framework and the gap between the parting flange and the master gets filled and flattened.

#3

Ok, so since my parts seem to have a lot of curves, its probably best to continue making them the way I do now. I use clay as a filler, are there any other materials I should use?

#4

Can you post a picture of something that requires a curved flange?

#5

We use an aluminium composite panel. It’s mainly used in the sign industry. 3.0mm thick with 0.2mm aluminium skins either side of a plastic core. You can cut it with a jigsaw and hand plane the edge and you can bend it without it springing back. Awesome stuff.

#6

Hi there, I currently use glassfibre cloth 1m x 1m square, lay it out on a piece of wax released glass the same size and apply polyester resin. I then add a second sheet of the glassfibre cloth and apply more resin and smooth out with a roller.

Once cured you have a hard but flexible flange material you can easily cut with a pair of sharp scissors.

#7

Ill post some pictures soon!

#8

Thats a good idea :slight_smile:

#9

It’s really good for flange. It is easily flexible to allow for curved parts. I also use a hot glue gun to stick it to the part.

Give it a try, it’s really good and pretty cost effective.

#10

My big issue is with attaching the flange so it becomes a single piece that can be waxed. Hot glue just doesn’t hold the flang in place.

#11

OK mate. I tend to do the flange in sections as it seems to stick easier, and if you break a bit off, the whole thing doesn’t come off.

I’m in the middle of making a mould for a Suzuki GSX-R 1000 tank cover at the moment. It should be finished tomorrow, I shall upload some pics when it is ready.