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Best way to remove mold from vacuum formed piece

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  • Member since
    May 2006
Posted by Rob Beach on Thursday, September 17, 2009 3:49 PM

I usually incorporate a bit of "extra" to the bottom of the master (or 'buck' as you've called it.)  This extra is delineated with a scribed line, which usually 'transfers' into the molding so I can easily trim it.  The extra allows for a "pry surface" that does not intrude on the mold area so if there is any minor damage to the master, no worries.

Also, make sure not to create an "undercut" situation, or at least not anything other than very minor.  For example, the F-16 canopy has a cross section that is greater than 180 degrees around (which is why Hase & TAM kit canopies, among others, have a mold line across the top - a two part mold is required!)  Vac molding such a shape means the part essentially traps the master, so some means of freeing it is needed.  For the F-16, the plastic is flexible enough, plus the profile (long dimension) is NOT undercut, so just flexing the sides outward will be enough to free the part.

Vac molding does not require release agents; just make sure your "engineering" of the master is paying attention to the "trapping" issue and you should get good results.  Part of the fun with vacforming is the experimentation, so expect to have some 'scrap parts' as you improve your technique.

Now, the above discussion is most relevant to molding canopies and small contoured parts.  If you are molding major components for say an aircraft model, then the "extra" I refer to may actually not be indicated since the idea is that the part will be separated from the 'sheet' at the juncture of part and sheet, so some precision is required.  Then it boils down to avoiding undercuts that would trap the part - unless you are working with complex, multipart molds!

Think of it this way: If I wanted to mold a sphere, I could in theory create a female mold with a tiny opening to "suck" the plastic into the shape (this is how milk jugs are formed, in fact, but by "blowing" with pressure, not using a vacuum.)  However, the part would be "trapped" in the mold unless I can split the mold apart along the equator-line (again, actually done with blow-molded parts.)  So, instead, I will split my master part in the middle to have two half-spheres, attach them to a flat surface and viola! a master that has no undercuts because the widest dimension of the part is facing the plane of extraction.  This principle applies to all molding, whether you are using female or male molds, and is the same concern for injection molding, casting, etc.

One extreme is when the "lost wax" process is used to cast intricate brass parts (such as those beautiful cast metal landing gear sets.)  In lost wax, the master part is made of stiff wax (jeweler's wax) which is then encased in a block of poured plaster-like material.  Once hardened, the ceramic mold is heated to melt out ("burn out") all the wax master.  Then the molten metal is poured into the mold, cooling into the cavities and forming the part.  Only problem - the part is completely trapped in the one part mold!  So, the mold is broken apart to extract the molding, so not only is the wax "lost", but so is the mold - which explains why such parts are pricey.  Molds must be made everytime a part is cast!  But such detail, ah!

Hope this discussion helps with your project.

Regards, Robert Beach

  • Member since
    August 2007
  • From: Carrollton, Texas
Posted by BraniffBuff on Friday, September 4, 2009 10:03 AM
I have found that the best way is to carefully trim away the excess plastic from the bottom of the molded part, then very carefully insert the tip of a #11 x-acto blade or similar between the piece and the buck. This usually lets in just enough air to make it easy to remove the buck. When molding canopies, I usually file/sand the bottom edges of the clear plastic flush with the bottom of the mold before trying to remove it.

I've had the same experience with tape frames on a canopy master, and used clear enamel to seal them in place. So I suppose Future would work as well.
Michael McMurtrey IPMS-USA #1746 Carrollton, TX
  • Member since
    July 2014
Best way to remove mold from vacuum formed piece
Posted by batai37 on Sunday, August 30, 2009 8:45 PM

Hi all,

Does anyone have any advice on how to make removing a "buck" from a vacuum formed piece easier?

Specifically, I'm making an aircraft canopy from a buck made of Sculpy.

I formed the canopy frame from Tamiya masking tape, which incidentally tends to come off when removing the buck from the molded piece. I've found that it's kind of difficult to remove the buck from the piece...is there some sort of release agent that makes this easier like with resin casting?

Also, will applying a coat of Future over the tape frame help keep the tape from lifting off when removing the buck? Any help would be appreciated!

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