ALWA MOULD D Application

Patterns and its preparation

A wide range of materials are appropriate for the cast (wood, plaster, plastics, leather, metal, acrylic, etc.). Polystyrene is less appropriate since it requires special precautions. Any material must be dry. In order to cast the material a casting box must be built around the pattern. The sides of the casting box are fixed with screws. Porous master patterns of plaster or wood must be sealed. We recommend to use our ALWA ACRYLIC SEALER (art. no. 9535000). Any pattern must be pre-treated with ALWA SURFACE TENSION REMOVER (art. no. 9500000), which removes the surface tension and ensures a smooth coverage of ALWA RELEASE LACQUER (art. no. 9510000). First, a thin layer of ALWA SURFACE TENSION REMOVER is applied on the prepared patterns with a cloth. After approx. 5 – 10 min. the ALWA SURFACE TENSION REMOVER is vented. Then, ALWA RELEASE LACQUER is applied with a brush or a spray gun. For fine structures several layers (min. 3 – 4) should be applied with a spray gun. ALWA RELEASE LACQUER is soluble in water, therefore, moisture penetration should be avoided. Hot air can accelerate the drying of the release film (the drying of the release film takes approx. 30 min. at RT).

Before casting, make sure that the pattern and the mixture of casting resin and aluminium powder have a temperature between 19 – 22 °C. At temperatures above 22 °C shrinkage may arise and at temperatures below 19 °C the cast material expands.  

Calculation of a batch quantity

a) Calculate the casting volume in litre. In order to compensate casting losses and miscalculations, we recommend increasing the batch quantity by approx. 5 %
b) Multiple calculated casting volume by 1.7 to receive the batch quantity in kg.
c) Batch quantity in kg corresponds to

  • 40 kg resin content ALWA MOULD D, comp. 1 + 2 and
  •  60 % aluminium spray grit, < 65 mµ.
d) Example: 20 litres x 1.7 kg = 34 kg casting compound

ALWA MOULD D component 1,
ALWA MOULD D component 2,
Aluminium spray grit, < 65 mµ,
Hardener powder( 3 % on the resin content)

Art. no. 6000…
Art. no. 6001…
Art. no. 4065025
Art. no. 5100001
13,33 %
3 % on the resin content
4,53 kg
9,06 kg
0,41 kg


Mix the resin components well. Afterwards add the filler into the resin and stir until you reach a homogeneous mixture and no aluminium lumps are left. Leave the finished mixture for venting until no more air bubbles appear. After airing, carefully stir the mixture. Then thoroughly mix in the hardener powder (3 % on the resin content) for approx. 3 – 5 min. Lumps of the hardener powder must be crashed before adding it into the mixture. Please note that as little air as possible should be stirred into the mixture. For larger batch quantities mix the resin compound in two or more mixing containers. In this case, the hardener powder must be added simultaneously. For homogenisation, the resin compound of two or more mixing containers has to be mixed among each other to achieve a simultaneous curing of the mixture. Only then you get a homogeneous hardener and temperature distribution (same reaction behaviour of the total mixture).

As the resin contains flammable solvents, ex-proof mixers should be used. We highly recommend using our ALWA SPECIAL MIXERS since they ensure that as little air as possible is stirred into the mixture. After the hardener has been stirred into the mixture and vented for 3 – 5 min., the mixture must be cast in a thin stream within 8 – 10 min. on the prepared pattern. First, the mixture is poured slowly into the deepest part of the pattern. In order to prevent that aluminium lumps are cast into the mixture, a sieve can be used. When the pattern is completely covered with the mixture, the rest of the material can be added faster. The curing process should be protected from the effects of cold and heat. After adding the hardener powder, the resin gel time starts after approx. 18 min. and a fast temperature increase can be noticed. The resin compound cures just as quickly. Reaction temperatures up to 130 °C can be reached. Since the resin compound cures quickly, patterns of wax can also be moulded. After the resin compound is cured, approx. 50 min. after the hardener powder has been added, the backside of the mould is sprinkled with aluminium spray grit, which then is spread with a hand brush (prevents a sticking at the back of the surfaces). Tools and containers should be cleaned with a solvent (e.g., acetone) directly after using. Before the temperature peak has been reached, the mould expands in length. Therefore, the screws of the casting box sides are removed to enable a free expansion. Cast drive-in nuts are very useful for demoulding. Depending on the master pattern it might be reasonable to wait until the cast has been cooled down to 60 °C or to RT.

Place the warm casting (especially flat moulds) immediately on a flat surface for cooling. For thin moulds a closed casting box should be used. Alternatively, they can be clamped on a level surface. While the mould is cooling, it shrinks to its original shape. Leavings of ALWA RELEASE LACQUER can be easily removed with warm water. The moulds are easily machinable (e.g., drilling, milling, grinding, planing, sawing, turning, etc.). Holes can be drilled in the mould and threads can be cut. But it is more effective to pour screws or nuts in the mould. Due to the dust development during the application, an extraction system should be used. After wet sanding and applying a polishing paste by using a polishing wheel, you get a metallic shiny surface. Small repairs can be conducted with our ALWA REPAIR FILLER (art. no. 3050001). The damaged area should be roughened and cleaned before applying ALWA REPAIR FILLER. In order to drill vacuum holes, we recommend using our ALWA DRILLS (art. no. 9006000).

Please consider the different thermal coefficients of linear expansion if something is screwed on the mould or the mould is screwed on a plate. Drill larger holes for the screws into the material, so that the moulds can expand.

Important notes to ALWA MOULD D:

ALWA aluminium powder
Our aluminium powder does not sediment during the pot life. Therefore, only our ALWA aluminium powder should be used.

ALWA mixer
With our mixers nearly no air is stirred in. The material is mixed from bottom to top. The hardener is stirred in quickly and homogeneously.

Temperature resistance of additional materials
The expansion coefficient of materials which are attached to or in the casting box should be equal to that of, for example, copper pipes and perforated aluminium sheets. No steel or wood shall be used.