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GElliott
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bullet Topic: Half-mask help needed
    Posted: 2/16/09 at 10:11am
We are about to make several half-masks for an upcoming production.  Luckily, we already have the negative plaster molds from long ago.  My question is does anyone have any experience with a product called Wonderflex.  We are looking for a quick solution to molding these masks.  Wonderflex seems like it might do the trick, but wanted to see if anyone had any pros and cons about it.  If you're not familiar with the product, here is a link about it:  http://www.dazian.com/html/wonderflex.html

We are also considering liquid neoprene and that is straight forward, just will take longer.

Thanks for any help on this.
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TonyDi
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bullet Posted: 2/17/09 at 3:40pm
This is interesting looking stuff but a bit expensive if you ask me. It's really nothing more than a heat formable thermoplastic and the size sheets they sell it in are rather large - nearly 4' X 5' and that seems a bit awkward - especially since you can buy thermoplastic sheets in smaller sizes, easier to handle and likely less expensive or that is MORE for the same amount of money.  The key is finding a plastics place that sells thermoplastic sheeting - and there are many.  IASCO sells it in smaller sheets - likely more face sized than huge.  Cadillac Plastics company might have distributors scattered across the country that should also have it. As well some hobby and craft stores handle thermoplastic sheets (likely smaller sizes) but they all come in a variety of thicknesses .20 .30 .40 .60 are the more widely used and "standard" craft sizes used for a wide array of projects.  So look close by and then go online - there are others who have THERMOPLASTIC SHEETING (you might try Googling that) and you might find it cheaper than these folks.  It can be heated in an oven if you're doing vacuum forming OR you usually can use a heat gun and press it into molds though usually the rule of thumb with molds is "hard into soft" and/or "soft into hard" with regard to the materials used.  Trying to model a hard - even flexible but hard plastic in a plaster mold or similar usually is NOT the best method. It CAN be done but it's more trouble than going with a plastic into like a silicone mold or a flexible soft material into a hard plaster or fiberglass mold.
 
Just some thoughts.  Look around if you have time....there are cheaper ways perhaps and MORE than one way to accomplish what you are trying to do.
 
Good luck
 
TonyDi
 
By the way NEOPRENE is just too difficult to work with - stick with thermoplastics that are thin enough to have flex and still be able to finish as needed. Neoprene MIGHT take some special paints to adhere and release agents to remove from molds, etc. Too much trouble in my way of thinking.  Although I know that liquid rubber thing is often used for a variety of things.
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GElliott
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bullet Posted: 2/18/09 at 9:09am
Well, the neoprene, from the research I've done seems fairly straight forward.  If the plaster is clean and dry, everything I've read says it should simply cure for 3-4 hours, pour off excess and let it cure for about 18 hours.  After that it should peel off and be able to be painted after it sets. 

Again, I've never worked with it, but several mask makers online seem to prefer it.  Just wanted to see if anyone else had actually worked with either products I mentioned originally and had any feedback to pros or cons of the products.

But, thanks for the info on thermoplastic, I'm researching it now.

Gene
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David McCall
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bullet Posted: 2/18/09 at 12:55pm

These folks sell smaller sheets.

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