Spray On Molding Gels
Instagel Spray is formulated for making large rubber molds where high volume production is required. This product cannot be hand mixed, it must be spray applied with special mixing and spraying equipment. The required equipment simultaneously mixes part A and B components together and sprays the product. InstaGel Spray molding gels cure more rapidly than our brush-on application rubbers (see our Brush-on Molding Gels product page). We recommend 2 types of spraying equipment for InstaGel Spray application; the first type is a small hand held dual cartridge spray gun the second is a much larger electric gear driven 2 component plural spray machine. The cost of the cartridge type spray gun ranges from $700.00 to $1500.00 USD. The larger electric spraying equipment ranges in price between $5000.00 to $12,000.00 USD. Both types of spraying equipment can be used with InstaGel Spray. The hand held cartridge sprayer may be purchased directly from Industrial Polymers Corporation or other suppliers.
A disadvantage of using the hand held cartridge spray gun is the added cost of the disposable plastic cartridges which only hold 1.5 liters of product and cannot be reused. The cost of the disposable plastic cartridges and mixer tips is approximately $8.25 per cartridge set and it takes approximately 4 complete cartridge sets to spray only one gallon of InstaGel Spray rubber. The cost of disposable plastic cartridges adds $33.00 per gallon to the cost of spraying your rubber. If you plan to use large amounts of spray on mold making rubber the more expensive electric spraying equipment may be a good investment over the long run and reduces landfill waste. The electric spraying equipment should be purchased directly from an equipment manufacture/supplier who can offer long term maintenance, technical support and training. We routinely direct customers to Spray-Quip Incorporated at 800-500-9109 www.sprayquip.com or Michael Engineering at 989-772-4073 www.michaelengineering.com for price quotes and help in selecting the spraying equipment which best serves your needs.
InstaGel Spray is urethane which becomes very thick after the part A and B components are mixed together. Having a urethane product which is very high in viscosity (a paste consistency) allows the product to be applied very thick on a surface without sagging or running down. Spray on rubber mold making rubbers are very help and time saving when you are making rubber molds from large 3 dimensional masters. A spray on rubber is also helpful if you want to spray into an open faced mold to make a large flexible rubber skin for animatronics applications. If you would like to make a rigid plastic shell instead of a flexible rubber skin we manufacture UraGel 760 which cures to become a hard surface. UraGel 760 is sometimes used in open faced silicone rubber molds to make large masks or reproduction suits of ancient amour. UraGel 760 can be sprayed into a silicone rubber mold ¼ of an inch thick or more to make high durability rigid plastic parts. Customers frequently use UraGel 760 over InstaGel Spray to create a hard supporting mother mold for their brush on rubber mold. The InstaGel Spray and UraGel 760 products are available in 5 gallon plastic pails and 50 gallon drum quantities. Please call 800-766-3832 / 713-943-8451 or email us for current pricing and delivery options.
We manufacture 3 spray-on gel products for making flexible rubber molds and 1 spray-on gel product (UraGel 760) which cure to be hard plastic. Instagel Spray 20 is the softest and Instagel Spray 40 is the hardest flexible spray applied rubber product we manufacture. The cured hardness of InstaGel Spray rubbers increase from 20 Shore A to 65 Shore A, see chart below.
InstaGel Spray 20 flexible (25 shore A) Good for making molds with deep under cuts
InstaGel Spray 30 flexible (30 shore A) Spray-on mold making flexible rubber
InstaGel Spray 40 flexible (40 shore A) Spray-on mold making flexible rubber
InstaGel Spray 65 flexible (65 shore A) Frequently used as a top coating for flexible foam construction.
UraGel 760 Hard (75 Shore D) rigid Spray-on mold back-up material or for making rigid parts in mold
Our spray-on gel products can only be sprayed by disposable cartridge or low pressure electric gear pump type plural spraying equipment. If you are pumping out of 5 gallon containers or drums it is important that the Part B storage container be thoroughly mixed each day before use. The part B component of InstaGel Spray settles out quickly in storage container and must be thoroughly mixed to insure InstaGel Spray cures properly when applied to your master. InstaGel Spray begins to cure in the static mixer spray tip and quickly gels on the surface of your model. InstaGel part A and B components are color coded so you can watch for color variations in the mixed product to see if your spraying/mixing equipment is functioning correctly. Variations in the color of applied InstaGel Spray indicates your equipment is not functioning properly. Product which is not thoroughly mixed will appear off color and weak areas or sticky spots in your mold will result. After mixing equal volumes of A and B components together our gels transform into a creamy paste consistency. You may apply our molding gels up to 1/2- inch thickness in a single application without sagging or running. These products remain in a gel consistency for approximately 10 to 15 minutes after spraying. We recommend you allow 24 hours curing before using the finished mold. Fabric or chopped fiber can be added to enhance physical properties of cured gels both rigid or flexible. Application of the molding gels should be done in a dry environment to prevent surface bubbling. Clean up should be done with solvents such as mineral spirits, Methyl Ethyl Ketone (M.E.K.), or acetone solvents. Both InstaGel Spray and UraGel 760 contain no V.O.C. solvents and are nonflammable, low odor products and classified as nonhazardous for shipping purposes. See material safety information for complete information.
InstaGel is a flexible, spray-on product for making rubber molds from objects or wall surfaces which cannot be placed in standard box molds (any 3 dimensional objects or vertical wall surface). After mixing, InstaGel Spray thickens to a creamy spread-able gel which can be applied onto vertical or overhead surfaces without sagging, or running. Within 24-hours InstaGel Spray cures to a tough rubber mold. Before applying InstaGel Spray, surfaces should be coated with silicone or wax mold release and must be free of moisture to prevent unwanted bonding or surface bubbling. Mold releasing agents must be used to insure easy removal of InstaGel Spray rubber mold from the master.
UraGel 760 is a rigid (75 shore D) Spray-on mother mold making material or low odor fiberglass replacement product. UraGel 760 is also used for manufacturing in-mold hard parts, reproduction ancient amour and decorative masks. Use this product any time you need to make hard durable parts from a large open faced mold.
UraGel 760™ is formulated for spraying hard mother back-up molds or hard plastic parts. It can be sprayed into rubber molds 1/2-inch thick in a single application. When fully cured UraGel 760™ forms a rigid “fiberglass like” polymer which is easily sanded or machined and painted to final form. UraGel 760™ is recommended as a rigid Mother Mold back up for flexible InstaGel Spray molds. Polyester fabrics and chopped fibers can be used with these materials to enhance strength and durability. UraGel 760’s thick gel consistency makes it easier to work with than fiberglass, no cloth lay-up required. Very thick sections can be created in a single product application, no flammable fumes or odor.
Procedure for making a brush-on mold from textured or carved wall surface or clay master;
1. Apply appropriate mold releasing agent (silicone spray, furniture paste wax) to surface.
2. Spray apply InstaGel Spray to entire wall area at the desired thickness (1/4″ to 1/2″ thickness). Allow to cure overnight before beginning step 3.
3. Apply appropriate mold releasing agent over the InstaGel Spray (silicone spray or furniture paste wax).
4. Apply UraGel 760 at the desired thickness (1/4″ to 1/2″ thickness) over the cured InstaGel Spray and allow 24 hours cure.
After 24 hours remove the InstaGel Spray rubber mold and the UraGel 760 back up mold from the surface. When you are ready to cast reproductions of the part lay the InstaGel Spray rubber mold into the rigid UraGel 760™ cradle back up mold. Reproductions of the wall surface can be made by applying urethane, plaster or concrete into your finished mold. The rigid back up mold will help your rubber mold maintain the proper shape when it is placed on the floor and filled with casting material. Always use mold appropriate release agents to prevent unwanted bonding of parts to your new rubber mold. Your mold will allow you to reproduce the exact shape and texture of the original wall surface from a variety of materials.
InstaGel Spray and UraGel 760 can be used as a bonding adhesive for wood, fiberglass, flexible foam, rigid foam and masonry components. Its paste consistency fills large surface gaps and holds pieces together, but hardens slowly enough to permit bonded parts to be fitted or adjusted while curing. These products will not dissolve EPS foams or styrene foams. Chopped fiber or fabrics can be with the UraGel 760 to increase strength. Fiberglass “Chopper Guns” are available which chop and simultaneously spew chopped glass fiber onto a surface as the UraGel 760 is applied.
InstaGel Spray bonds well to other materials and its rapid set time makes it an excellent flexible bonding adhesive for foam, wood or masonry production line assembly.
UraGel 760™ is also used as adhesive, surface filler and hard coating over expanded polystyrene (E.P.S.) foam.
UraGel 760™ can be painted with solvent base or water base paints (see Helpful Product Tips below). UraGel 770™ bonds well to other urethane materials and its fast set time makes it an excellent rigid bonding adhesive for foam, wood or masonry production line assembly.
Helpful Product Tips
It is easier to lift a paint job out of a silicone rubber mold than to later try and paint over cured urethanes. When customers use UraGel 760 to make reproduction ancient suits of armor or shields or masks they usually apply paint or primer inside the silicone rubber mold first before brushing in UraGel 760. When the UraGel 760 cures it will completely remove the paint layer from the mold, so your part comes directly out of your mold with a perfect paint job or primer layer. This trick works best with solvent based paints or primers. Water based paints will make the UraGel 760 bubble or foam as it cures in the mold. For this procedure we recommend using solvent based aerosol spray can paints from the local hardware store. Allow aerosol spray paint to fully dry or speed drying with heat gun. When paint is dry apply UraGel 760 into mold and allow full curing. When the cured UraGel 760 part is removed from the mold it will lift paint layer from mold and have a perfectly painted or primed surface. This in mold painting method saves time, produces better looking smother finish and is more durable and scratch resistant than ordinary painting.
When making brush-on rubber molds from wood, concrete, plaster, water based clays or natural stone, extreme care must be taken to prevent sticking of InstaGel Spray to master. Moisture coming out of wood, concrete or plaster will cause bubbles in your rubber mold and make spray-on silicone based release agents fail. You should paint or seal these materials and use heavier wax type release agents to prevent sticking of Instagel Spray molding rubber. When making brush-on molds paint or seal with a fast drying solvent based paint or sealer, let dry then use Johnson’s furniture paste wax or mold release wax to prevent sticking. Do not use car wax or liquid waxes because they usually contain water. Furniture wax or purpose manufactured mold release wax does not contain water.
Have all materials at 70° – 85°F before mixing. Mix B component thoroughly in storage container each time before you begin spraying operations. Mix B component storage container thoroughly for 1 minute with electric or air powered drill and Jiffy® mixer drill attachment (Jiffy® mixer drill attachments are available from Industrial Polymers in 3 sizes for 1 gallon can, 5 gallon buckets and the largest mixer for 50 gallon drums), avoid whipping air into the part B solution as you mix. Close storage containers tightly after use, liquid components of Instagel Spray will absorb atmospheric moisture when exposed to air, causing the part A component to hardened in storage container or bubbles and foaming to occur when part A and B components are mixed together.
Follow equipment manufacturers directions for clean up procedures when you have complete
Spraying operations. Clean up should be done with solvents such as mineral spirits, Methyl Ethyl Ketone (M.E.K.) or acetone, never use water to clean when working with these products.
Water or moisture exposure will accelerate curing of these products causing bubbling and poor physical properties of cured product.
InstaGel spray & UraGel 760 liquids should be stored in the original, unopened containers in temperatures between 64°F and 86°F (18°C and 30°C). Shelf life of materials when kept in unopened, sealed containers at the recommended storage temperature is six months. Container should not be opened until ready for immediate use.
Health and Safety Information
Read InstaGel Spray & UraGel 760 Material Safety Data Information thoroughly before using these products. Copies of the most current product safety information may be obtained at
www.industrailpolymers.com or by calling 1-800-766-3832 or 713-94308451.