Many business partners know the casting process is important, but seldom know why, how, and what is a key point inside. I don’t want to explain one by one, so write this article today.
Why is Casting Important?
The casting process directly affects the final sculpture’s precision, uniformity, and overall perfection. Below are the reasons why the casting process is important:
1. Affect Final Sculpture Size and Shape
Accurately casting the liquid resin into the mold is essential to ensure the final sculpture’s size and shape meet the casting request. Uneven or leaking casting can lead to incomplete shapes or size deviations in the final product. Below are some reasons why casting accuracy is crucial to the quality and performance of the casted sculpture:
- Uneven casting can result in overfilling or underfilling of liquid resin in parts of the mold, leading to incomplete shapes and size deviations. This can affect the sculpture’s quality and usage, and in some cases, render the product unusable, leading to increased production and time costs.
- Leakage casting can prevent the liquid resin from filling all gaps inside the mold, resulting in incomplete shapes and affecting the sculpture’s functionality and stability.
- Therefore, it is essential to ensure accurate casting to achieve high-quality and high-performance casted sculptures.
2. Affect Final Sculpture Texture and Performance
Product texture and performance are crucial factors in the mass production of resin sculptures for home decor. Failure to control the liquid resin’s flow rate and temperature can lead to the following issues:
- Bubbles: If the resin flows too quickly or the temperature is too high, it may result in bubbles during the casting process, which will affect the final sculpture’s appearance and quality.
- Defects: If the resin flows too quickly or the temperature is too high, it may cause internal defects in the sculpture, leading to a reduction in its strength and lifespan.
3. Affect Final Sculpture’s Appearance
Bubbles and other defects in the casting process can adversely affect the quality of the sculpture, causing surface imperfections and affecting the overall product’s aesthetics and texture. The casting speed, angle, and method are also essential factors that can significantly impact the final sculpture.
Therefore, it is crucial to pay close attention to the casting process and control the casting speed, angle, and method to achieve high-quality and visually appealing sculptures.
People Are the Key to Quality
Experienced workers with rich skills play a vital role in the casting process. Due to the liquid nature of resin, the process requires great precision and meticulous handling. Workers need to control the liquid resin’s temperature, flow rate, casting time, and position to ensure the casted sculpture meets the requested quality and shape.
To achieve optimal results, workers must have a deep understanding of the resin material’s characteristics and make adjustments in the casting process where necessary. For instance, different materials may require varying casting temperatures and times to ensure the casted sculpture is in the best possible condition.
On-site problems may happen during the casting process, such as air bubbles, defects, or other issues. Experienced workers can find out these potential problems and solve them on time to ensure coming molded sculpture quality and avoid unnecessary defective rates.
Tips and tricks for creating resin cast sculptures
1. How to Choose the Right Resin Material and Color?
- Applicability: The first step in choosing the right unsaturated polyester resin material is to consider its applicability. Different types of resin have different usage and features, so it’s essential to choose a material that suits the sculpture’s specific application scenarios.
- Quality: High-quality material is crucial to ensure the final sculpture’s quality and use life. It’s best to choose a well-known resin supplier to work with to give you enough assurance.
- Color: Choosing the necessary raw material color is also important. Unsaturated polyester resin is commonly transparent or white but can be colored by mixing pigments. It’s essential to choose strong color lock pigments to ensure that the coming sculpture’s color is a good result.
- Production cost: Resin and pigments are two factors that need to be considered when choosing the right material. It’s important to select the right one based on the product’s needs and budget.
2. How to Deal with Resin Bubbles and Defects?
Solutions for bubbles and defects depend on the real situation. Here are some common methods:
- Preventive measure: the factory needs to take necessary preventive measures to reduce the bubble and defect rate. For example, controlling the liquid resin temperature and flow rate can avoid mold surface impurities and grease.
- Vacuum degassing: put the mixed resin liquid into a vacuum degassing machine to use negative pressure to drain out bubbles.
- Pressure degassing: put the mold into a pressure tank and use high pressure to drain out inside mold gas before casting. This way can reduce the bubble happen rate somewhat.
- Manual venting: Use a needle or small knife to pick up surface bubbles carefully when casting resin liquid to mold and let them dissipate naturally.
- Repair defect: use polishing and filling methods to fix ready defective parts. Large defective products may need to be reproduced.
