Working with EpoxAcast 655

Benchtop/Desktop Injection Molding with Aluminum Filled Casting Epoxy

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Aluminium filled epoxy resin is intended for low run injection molding production. I created this page to make a walk through of the process.

JPEG Image - 577.58 kB - 10/07/2016 at 00:54


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JPEG Image - 557.67 kB - 10/05/2016 at 16:34


JPEG Image - 623.74 kB - 10/05/2016 at 16:34


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  • 1
    Step 1


    Wax paper, masking tape,plastic drinking cups,large mixing Popsicle sticks (make one end flat); large paint stirring sticks, Mixing Turbine (buy or make your own), hot-glue sticks, painters horse-hair brush, disposable funnel cups; Acrylic Sheets; disposable gloves

    Niche Materials:

    EpoxAcast 655, HT Hardener, Ease Release 200

    Hardware & Tools:

    Toaster Oven, Kitchen gram scale, Power Drill (mixing turbine), chisel, pliers, hot-glue gun, scissors, safety glasses

  • 2
    Step 2

    Mold Setup:

    hot-glue your mold into an (laser-cut) acrylic box.

    Spray mold release onto parts, do two+ applications, 5 minutes apart, wait 30 minutes to fully dry, you can brush on the release as well.

    Prepare Space; place wax paper on floor and surfaces.

    Pre-Stir/Mix (by hand then use drill turbine) Epoxacast "A" Resin for several minutes each; Mix "A" (100 units) to "B" Hardener (8 units). Pour molds (using funnels). Measure by WEIGHT not by volume.

    Let it set for 24 hours; heat cure in toaster oven two hours at 175F; then three hours at 300F

  • 3
    Step 3

    3D Printing Observations

    Objet resin prints did not set correctly, possbily not enough mold release, or possibly due to objet verowhite plus reacting with epoxacast materials. I would recommend adding the extra step of a silicone mold.

    3D Printed ABS filament was vapor polished- by heating hardware store Acetone (some nail polish removers have additives that don't work well) inside an asparagus steamer on a electric hot plate (and also outside in a well ventalited area). You can cold polish with a rubber maid box with your parts elevated on a metal hot pad/ cooling sheet.

    Create an index/keying feature in the original 3D printed part, this will help line up the A/B parts accurately, also the finished molds were faced using a vertical hand mill.

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