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hi everyone my name is Matsui and in
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this video I'll show you how I've used
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this soft squishy like polyurethane to
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make these Ironman masks so a lot of
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like improvising or testing was involved
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so I'll go through all the steps of what
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I have learned and explain you how to do
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like a good finished part so it's all
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starts with the mold so I'll be coding
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the pre molds that their hats to make
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like a new mold so the first layer would
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be the gel coat if you want to see more
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details about mold making you can check
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out my youtube channel you'll find some
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mold making videos on there as well so
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the first layer is the gel coat and then
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you wait for it to go tacky and what I
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would normally do what's making molds is
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using the Uni mold system so it's better
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to make like stable strong moles in one
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go
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but I decided to try this out so it's a
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cheaper option to go it's regular
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fiberglass and just like the normal
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laminating polyester so one thing to
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keep in mind when using these like basic
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regular polyester resins is not to build
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up too much too much thickness in one go
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because it could go exit thermal and
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warp your mold around so a good solution
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is to apply a first layer
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wait for it to cure then you send it
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back down just to have like a good
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mechanical grip for the next layers
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coming on top and then I did this in
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three times so it's quite a nice build
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up it's a strong mold and it's a stable
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mold that way so as you can see here the
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last layer is applied so it's a
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finishing layer and about four layers of
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450 grams fiberglass was added so a
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pretty thick strong mold for this piece
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because there could be a lot of pressure
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being involved with the polyurethane
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expanding so you'll see later on in the
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video what I mean which the polyurethane
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expanding so as you can see the mold is
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about five millimeters thick and I don't
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know in inches how much that would be
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but you can check it on Google and so
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the next step is to add a release agent
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so the easy lease is
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common release agents for various types
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of resins and coatings so I'm using this
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one there are specific release agents
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for poly urethanes as well I think it's
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a PW I'll try to add it in the
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description and below so what I did
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there is to make a closed mold I have to
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finish the part first so I've started to
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at making first part with fiberglass
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into the mold and then I'm just like
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filling the volume with expanding
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polyurethane foam so this is not sped up
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as you can see it goes quite rapidly so
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it's a heavy reaction going on there and
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it's a foam that will expand about 16
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times in volume so this is a
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polyurethane and you cannot compare it
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with building polyurethane because this
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is more dense in its cells like the
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structure of the foam but that way we
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were able to fill the entire void and
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then on top we'll add a second layer so
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here I'm just trimming everything up to
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the side like this would be the size of
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the part that I want to create with the
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polyurethane so I'm just cutting
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everything flush sending all the
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polyurethane flush and then I'm just
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using some masking tape all around the
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edge to avoid having the polyester resin
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that we'll be using right here dripping
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off the sides because this part still
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has to fit into the mold that we've made
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previously so what I'm using is a sheet
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of plastic and I'm laminating the shape
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roughly onto the plastic first and then
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I apply it onto the foam that we had so
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once cured I can send it down just to
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remove all the erased edges because we
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want a smooth surface surface as well
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right here because the surface will be
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exactly the same on your parts that
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you'll be making in polyurethane and so
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the thing is it's very hard to sense or
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to correct mistakes on a polyurethane
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part if you're making fiberglass parts
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you can still send it down at some bar
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now like I did here but you cannot do
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that on the finish
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Bartz it's exactly the same with silicon
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for example so I'm using an easy to
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sense topcoat here so it's um it's like
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very easy to sense and to bring it to a
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higher level of gloss so I send it till
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800 because I knew that the mold will
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still have to be sanded after that so
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I've added some release agents to make
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sure that's nothing which stick onto
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this parts or the mold and then it's
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just again like in the beginning
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applying the gel coat and then applying
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multiple layers of the fiberglass so the
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easier thing here is that it's an easy
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shape so it's like just a rectangular
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shape so I'm preparing everything on a
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sheet of plastic again and then apply it
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on top so I've added I think the same
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amount of layers and like I said in the
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beginning of the video is very important
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because a lot of pressure can build up
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with polyurethane expanding and so
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that's why it's very important to have
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like a stiff and a strong mold ideal you
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would have like aluminium molds that are
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CNC milled but due to the expenses of
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that mostly it won't be an option for
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like small numbers of parts that you're
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trying to make so here we see the
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backing releasing quite easily then it's
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just a matter of like bring it back to a
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high gloss and then adding a few venting
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holes so that the polyurethane can
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expand but it wouldn't create like too
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much pressure inside the multi one
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pressure but not too much so I'm adding
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some release agent again and now I'll
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show you the steps that I went through
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so this was the first part then we got a
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little bit better this is the second
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part and then like we improve along the
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way to find like an even better parts
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till the best-looking parts in my
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opinion you could get with a top it's
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like called the in mold coating that
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will create like a nice soft and shiny
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plasticky feel onto your parts so here's
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how it go so I've got the polyurethane
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yeast 60 foam I've used it previously in
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a tutorial that was quite
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and so I decided to make like a better
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video now just to explain how everything
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goes because the first video I shot I
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think it was around six years ago and
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the quality was likely to a shot on a on
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a potato so it's very bad quality so
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this should be a big improvement
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so how everything works is that you
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don't need a lot because it will expand
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quite a bit so I'm using the a
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components so it's it's called V shirts
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or the brand L edits into the
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description and below is from fall semi
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Benelux and you can probably order it
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online so that was the first part and
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it's like the big unknown to begin with
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because you don't know how much it will
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expand and how big it will get so I've
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did the second try and I was just
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running a bit short in the amount that
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was needed to be used so now that I know
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how much volume I need to fill I can
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start doing it with the closed mold so
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um so you gradually go up and then when
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you find the perfect recipe you can
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start closing the mold and I was running
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like a bit short to create like a good
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amount of pressure here because the
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pressure is important to create like a
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nice skin on your part so this was like
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I would say like a good results but I
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was looking for something a bit more
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shiny a bit more like finished the good
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thing with this is that you can go
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through a lot of like prototyping stages
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in a short time because it cures quite
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rapidly so I think I did - the molding
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after around 20 minutes then it's like
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in a B stage nicely cured so this means
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that it will cure a bit more once it's
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out of the mould but it's easy to handle
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now and remove it from the mold so now
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the big improvements is using the in
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mould coating so the in mould coating
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will create that nice almost like gel
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coats finish so it's very you can
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compare it to a gel coat but made out of
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polyurethane to create those like shiny
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skins polyurethane soft parts parts so I
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was a bit shocked to see how take it to
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us so it's like
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bondo but once mixed with he catalysts I
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think it was around the mixing ratio is
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five on one I've mixed about 150 grams
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for the two parts and then you can apply
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it it's like a bit of a jam
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it's a honey texture texture it's
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residue that you apply onto your mold
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and it will cure quite fast as well so
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you have to move quickly make sure
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everything is ready and then you can
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proceed with the steps that we did
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previously it's pouring the polyurethane
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that will expand so you want to have the
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animal coating in at a key stage but
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secured enough to create like a nice
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come out chemically bounce between the
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soft film that will expand and the shale
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that you create it around it so the hard
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part was mostly removing the ice
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I was running short of materials but if
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I would want to make it better I would
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apply two coats of the in molds and then
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do the the casting of the expanding foam
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at the end so very important is to label
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your molds because I will probably
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forget in six months how much I've used
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so here you can see in grams how much
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was used of each substance so here is
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the results it's a squishy soft Iron Man
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mask so this could be used for furniture
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I would think of something that needs
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some textures around a parts that needs
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to be soft like grips and so on so this
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is a result and it will come back to its
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shape after you pushed it so final step
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would be trimming of the edges I did it
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with a piece of sharp scissors and this
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is the result so I hope you like this
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video don't forget to Like and subscribe
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and see you guys in the next one
