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00:00:10
expanding flexible foam now in today's project
I'm going to show you one way of creating custom 00:00:17
flexible foam inserts for all types of drawers and
cabinets for any type of sensitive electronics and 00:00:25
camera equipment now there's a couple of pros
and cons to using flexible foams to make you 00:00:33
a custom inserts like this of course you can buy
your foam sheets and cut out any insert that you 00:00:38
want but those foam sheets are not very durable
they come in open cell structures and you don't 00:00:45
have much of a choice for densities whereby if
you're casting with liquid foams you can choose 00:00:52
your own foam density you can pigment the foams
they're closed cell structure a lot more durable 00:00:57
and of course you can customize to any shape and
design that you want to make the insert for now 00:01:05
in this case we're gonna make two inserts that
are specifically for the camera equipment that 00:01:12
we use here at the studio now the first step
would be to actually take some measurements 00:01:17
off the equipment that you want to house and I'm
just going to loosely write some numbers down that 00:01:24
I can base my inserts I'm going to be making for
this custom box so to say and for these inserts 00:01:34
I'm gonna be using a cardboard tube for the round
pieces and some wood blocks for the square pieces 00:01:41
I'm gonna cut these to the sizes that we noted
earlier and then I'm gonna proceed to seal it 00:01:49
using some sanding sealer and I'm gonna apply
at least two coats of this to seal the wood 00:01:55
pattern so it doesn't show up on our casting
the cardboard two pieces that we cut up to use 00:02:02
a space holders for our casting are also gonna
get sealed with the same sanding sealer so once 00:02:11
all these inserts have dried we can proceed to
attach them to a board I do need some oil-based 00:02:17
clay and as you can see here I have a bend that
says urethane only and what that means is that 00:02:23
the clay inside has been has been in contact with
urethane products previously and we want to keep 00:02:30
it as such so that we don't cause any kind
of cross-contamination keep in mind that the 00:02:35
oil-based clay are reusable and you want to keep
using them as long as possible once the blocks 00:02:43
are glued down with some hot melt glue I'm gonna
run a bead of that clay around these blocks for 00:02:51
two reasons first I'm gonna hinder any of the
foam making its way underneath that block and 00:02:57
secondly it's gonna leave a nice smooth edge on
my final casting so before we move on to the next 00:03:05
step of our project it's really important that
we put a release agent down on our pattern and 00:03:11
because we're using urethane foam we're gonna use
a release agent that's specifically developed for 00:03:17
this type of material this is ease release to a31
and we're gonna apply two layers off the material 00:03:25
to the entire pattern and allow it to dry for
about 20 to 30 minutes make sure that you don't 00:03:31
allow this material to pool up in sections of
your mold box because it will influence the way 00:03:37
that the final pattern is going to look it's
really important to understand and know that 00:03:45
not every release agent is the same and choosing
the wrong release agent for this application can 00:03:52
actually cause your casting material to collapse
on itself so make sure that you use the correct 00:04:00
release agent when dealing with urethane foams
the release agent is allowed now to flash off 00:04:08
for about 20-30 minutes before proceeding on to
the next step now to construct the actual mold box 00:04:16
I'm gonna go ahead and cut some melamine board and
I already pre-measured these out and I've cutting 00:04:25
them to the right sizes than I need now in order
to get a really nice finish on our casting it is 00:04:32
important to use a back pressure plate and that's
what we're making here now what is back pressure 00:04:39
back pressure is basically the pressure that's
created when the expanding foam inside your mold 00:04:46
box hits the pressure plate and then starts to
push that pressure back into the mold creating 00:04:56
a much better surface finish on our casting now
the way to achieve a good back pressure from a 00:05:04
back pressure plate is to have the vent holes on
the pressure plate located very conveniently in 00:05:11
the right size so that the foam can expand fully
give enough pressure to the front the face of our 00:05:19
casting yet won't build up too much pressure
inside the mold box where the mold box itself 00:05:25
could actually distort or break now the basic
formula for placing of the vents will depend 00:05:34
on the size of the mold but usually it's best to
place the vents along the edges of the mold where 00:05:41
they gonna make sure that the casting inside the
mold box has fully filled with material now fewer 00:05:49
vents allow more back pressure and a better finish
on the parts but again keep in mind that there is 00:05:56
that possibility of the pressure breaking the mold
box so you may need to adjust your vent placement 00:06:06
and vent quantity so now that the mold box has
been constructed we can place the pattern our 00:06:16
pattern down into the box and then we're going
to secure it using some screws you want to add 00:06:23
enough screws so that the pressure from the foam
does not distort or even break your mold box so 00:06:29
rule of thumb here is about every two to three
inches I like to put screw and of course I pre 00:06:36
drilled these holes because this is a melamine
board and these are particle boards and they will 00:06:43
easily strip and bow and crack so pre-drill any
time that you're using such laminated materials 00:06:51
as particle boards now before we start mixing our
material it is very important that you put a layer 00:07:00
of the easterlies 2831 over any surfaces that the
phone will be touching and you don't want it to 00:07:08
stick to that includes the event holes that's
where the foam is specifically gonna get soaked 00:07:14
in and stuck in so it's very important to release
any surface where the foam is gonna be in contact 00:07:20
with now for this project we decided to use the
Flex foam at 10 this is a one to one mix ratio by 00:07:27
volume polyurethane expanding foam it has a self
skinning and closed cell feature which allows us 00:07:36
to cast really nice finishes to our projects and
you'll see what the addition of backpressure the 00:07:44
actual face of our casting is gonna come out nice
and smooth and it's not gonna have any void or 00:07:50
open cells now this particular foam expands about
six times its original volume if you ever wonder 00:07:58
how much your material mold box like this is going
to take there's actually a really easy way to find 00:08:05
out you don't have to just guess and pour and
you can top off the product afterwards surely 00:08:12
but there is a material conversion calculator on
our website that's going to help you determine 00:08:19
how much product is needed for you to fill up a
specific void so if you haven't used that tool 00:08:27
yet I recommend checking it out you can do all
kinds of casting brush on all kinds of different 00:08:34
application and all kinds of different materials
that we have are available in that chart to help 00:08:40
you out determine how much material you're gonna
need for a specific project now before you start 00:08:47
actually mixing the product that's important to
actually lay out the tools that we're going to be 00:08:52
using for this project and as you can see here
I have actually two drills one has the turbine 00:08:59
mixer and the other one has the screw attachment
on it that way I don't have to switch back and 00:09:06
forth between the attachments when I'm working
with a very short pot life material like the 00:09:13
Flex foam it's really important that we premix
the two components separately before combining 00:09:20
them together the Part A and Part B should be
mixed thoroughly before it's dispensed out of 00:09:26
the original containers and this should be done
every time before you go to use the product it 00:09:32
doesn't matter if you mixed it an hour ago and
then set it aside you want to give it a quick 00:09:37
mix one more time before you actually go to use it
so because this is a by volume dispense ratio I'm 00:09:46
gonna simply dispense the Part B first the Flex
foam at 10 is naturally a bright white color and 00:09:54
to get away from that bright and screamin color
I'm gonna add a little bit of the so strong black 00:09:59
to our Part B off the flexible foam I'm going
to stir that in and allow the black pigment to 00:10:08
fight that initial white color off the material
so when we cast it it will turn into a nice soft 00:10:16
grey so now we're combined all the part B's into
our five gallon mixing container I can go ahead 00:10:24
and dispense the Part A the real trick comes now
once you combine the Part A and Part B together 00:10:30
you don't have much time you want to have all the
tools you need ready to go the benefit of using a 00:10:37
turbine mixer like this as the fact that you can
work fast since you don't have much time with this 00:10:43
product you can mix a much more thorough so the
combining of the Part A and Part B is going to be 00:10:51
much better which gives us a much better surface
finish and of course the air that you whipping 00:10:58
in through the foam is gonna give the foam a
much better rise than if you just mix by hand 00:11:04
the expanding foam zoo actually want to whip in
as much air as possible into them to give you a 00:11:11
much better rise and a turbine mixer like this is
gonna allow us to do just that so from the time 00:11:18
that we pour the two components we have about 15
to 20 seconds to mix them thoroughly the foam will 00:11:25
start expanding even if you're still working it
it will start expanding and you're gonna have a 00:11:30
mess on your hand if you don't act fast so a
turbine mixer like this is gonna do a really 00:11:37
good job of combining the Parts A and B together
now when you're finished with the mixing off the 00:11:43
turbine mix are you gonna still go back in and
scrape the side off the mixing container with a 00:11:49
flat edge mixing tool so we'll mix it get it into
your box into your mold box and here you can see 00:11:57
that I poured it over the blocks themselves
to kind of give it a nice first coating and 00:12:04
then let the foam rise inside on its own and
here you can see I'm just gonna go around and 00:12:11
tighten all the screws down again this might be a
little bit overkill on the screws but I rather be 00:12:17
sure that the pressure inside that box is not
gonna actually break the Box open so now while 00:12:26
we're waiting for the phone to expand we're gonna
take couple seconds to clean that mechanical mixer 00:12:32
using some B natured alcohol this is the best
time to clean your tools while the material is 00:12:37
still liquid and fresh when it starts to actually
expand and harden you're gonna have a really tough 00:12:43
time cleaning that off so a little bit precaution
here goes a long way to keeping your tools clean 00:12:50
so now that the mixer is clean we can devote
ourselves to watching the foam rise and you 00:12:58
can see here after its initial pot life which is
only about 50 seconds so within a minute you're 00:13:05
gonna see that foam rising and it's gonna start
to rise above and out of your mold box if you have 00:13:11
enough material in there the foam is allowed
now a full cure for 2 hours before be molding00:13:20
after the two hours any of the extra foam that
came out of our venting holes can simply be cut 00:13:29
away and then the entire mold box can be taken
apart 2d mold our actual casting you want Adam 00:13:38
oldy slowly as not to rip the actual foam and
voila here it is you can see that the actual 00:13:47
face of our casting looks really nice the cell
structure off the foam is very uniform very even 00:13:55
now remember you can see around that hole up top
that the edges are very soft and that's where that 00:14:03
clay came in that I put around the edges off the
blocks as I was preparing the pattern all right 00:14:12
so now that we deem old it the foam out of our
mold box we still have some of the residue of the 00:14:19
release agent and some of the clay that actually
transferred onto the foam and to remove that we're 00:14:27
gonna use some naphtha it's gonna remove any kind
of grease and release agent that was left on the 00:14:35
foam and won't damage the actual foam itself the
last thing you want to be doing is be transferring 00:14:42
these release agents and oil clays onto your
sensitive camera equipment so to prevent this 00:14:50
a cleaning is strongly recommended so now after
the foam inserts have been cleaned they can be 00:15:00
inserted into the places that they were made for
in this case it's this cabinet here and as you 00:15:07
can see all the equipment fits snug and perfectly
into the places that it was made for now if you 00:15:18
got inspired by this project and you would like
to purchase some materials to make your own you 00:15:23
can do so by visiting any one of our distributors
around the world so there you have a simple and 00:15:29
easy way to make your very own custom fly the foam
inserts for a variety of applications using our 00:15:36
flexible foam system now if you have an idea about
what we should do next please let me know down in 00:15:41
the comments below and if you'd like to see more
videos like this please hit the thumbs up button 00:15:46
now to keep up with our latest mold-making
and casting videos remember to subscribe00:16:01
youDescription:
In this mold making how-to guide video, Milo shows the steps to create a custom made foam insert for electronics or other delicate equipment. The insert is created using FlexFoam-iT!™ X 10 pound pourable urethane foam. Once the foam cures, the insert can be used in a storage drawer, travel case, or anywhere a piece of equipment would benefit from supportive cushioning. FlexFoam-iT! Series - https://www.smooth-on.com/product-line/flexfoam-it/ --- Make It Now! with Smooth-On https://www.smooth-on.com/ https://www.facebook.com/unsupportedbrowser https://twitter.com/SmoothOn https://www.facebook.com/unsupportedbrowser https://www.google.com/+smoothon -~-~~-~~~-~~-~- Adult Supervision Required Keep Out Of Reach Of Children -~-~~-~~~-~~-~-
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