I am making a prototype of something, but I need to first obtain some sort of moldable material. I am unsure as of whats readily available. It needs to be rather flexible, and able to retain a molded shape. The only thing that is coming to mind right now is mesh chicken wire, then coated. It isnt a complex unit, but the sooner I can make it, the better. Sorry I cant be more specific . Any help is appreciated.

 

How big is this top secret prototype? My brother is studing occupational therapy and they use some sort of plastic to make splints. You put it in hot water, mold it and it holds the shape after it cools down. It's expensive, so not good for something big.

How about a styrofoam block? Shape it, then cover it with fiberglass.

 

Its bigger than a breadbox, but smaller than a Geo Metro. Probably end up being 6-8 sq. ft. of material. It doesnt have many complex angles or shapes. It would be nice if a sheet of plastic or something was available.

 

Helping with very little info given

How about Modeler's clay ?

How long does the product have to be plyable

 

Yeah, sorry I cant be more specific. Dont want any of you walking off with my beer cozy/back scratcher idea....oh wait...


In all honesty, a few minutes would probably be enough. Just long enough to be able to contour match. Its a rather simple design. There are a few gradual shapes, some flat faces, and only a couple arcs. Thats why my first thought of coated chicken wire seemed like it might work (possibly wire covered with a layer of duct tape, and then a sealing agent...to maintain rigidity and still be slightly flexible). I can mold that stuff real easy, and I have some thick coating agents at my disposal.

 

Man...you have GOT to tell us what you're making when you get it done!! Curiosity is at it's height!

 

"Duct-Seal"???

Expandable foam (insulation). Then trim with an electric carving knife.
(Build a box from plywood. Use screws. Fill with foam. Disassemble box and trim when foam has set.)

Your chicken wire idea and fiberglass mesh / resin. Or substitute 'Bondo.'

Glue up balsa wood and carve.

???????????????

 

Thats what I was thinking...... Great Stuff
Strong, paintable, easily carved.

Other than all that....the clay is the best way to go.

 

Call an art supply store and see what the sculptors/artists use. My wife has used alginate to make molds of peoples faces. You mix it like plaster and wrap the item with gauze and slap the stuff on.

If money is not an object there's an item used to make a mold of a horses back so you can send it to the saddlemaker. It starts as a flat thin sheet, you heat it in the oven to 175 and then mold it to the horse or item, or to the wanted shape. It takes about 5 minutes to harden. Costs about $75 for one sheet though. If interested google "equimeasure".

 

shop class we used to make stuff out of plexiglass. heat a square of it in an old electric frying pan. then toss it onto a pegged board to give it the shape you want. but can't work with it for very long before it cools and gets hard again. big peace might be able to heat it enough in the oven

 

I have heard that the spray-in body panel filler is great - but also kinda high in price to use very much.

Is there a commercial version?

(contractors prices)

 

Paper mache over a balloon can work for the arches. You can make the arches as big or small as you want. There's also a way to make plasctic-like material out of milk and vinegar. I'll look for it.

 

Okay, 'Mr. Specific', wink-wink, I've got an idea. The alginate would be tempting if it was smaller than a shop vac. That stuff works great but is not cheap. I bought a few bags of it from a dental supply store. When mixed properly with water I was able to put my baby's hand in in. Waited for about 45 seconds for it to set and it stayed flexible enough to release his hand. Then I filled the molded cavity with plaster of paris. Then after waiting a couple hours, voila, I carefully carved away the alginate mold and had a 3d cast of his hand. Is that what you are trying to do; cast the shape of something fairly large?

If so, here is another, more economical idea:: Go to a local boat store or ship storage yard and get a partial sheet of the boat winter wrap. They come in many widths and lengths. Hopefully it won't cost too much. Then I would put a thin film of lubricant, like PAM cooking spray on the item you want to make a mold off. Then place the sheet of boat wrap on it and slowly and carefully work your way around the item with a blow dryer/heat gun and use your hand in an oven mitt to force the wrap down on the curves and creavaces of the item. If done slow and right, you might be able to completely make a 3d mold of your item. Now the sheeting might not be as rigid as what you need, but without more details on what you are trying to do, we're all just stabbing in the dark. I would wager that you are going to be making a fiberglass mold of something. If that is the case, then you might be able to carefully apply some fiber glass and resin on the outside of the shaped boat wrap to give it more strength before making the inner mold.

 

play-dough

 

Dude!!! That is just tooo funny!!! I laughed out loud at that one. I would not have thought of that. It sounds funny, but it might be one of the cheaper easier ways to go. It might actually work.


I was also thinking, if you're as cheap as I am, I might be temped to take my truck and shovel down to the local river bank or stream and load up with a truck full of natural clay. Then when yer done with it you could take it back and just dump it where you got it.