PU rigid foam wood-like molds are divided into two major categories: soft molds and hard molds. Further subdivided, there are silicone molds, resin molds, steel molds, aluminum molds, and so on. The design of molds should conform to the general principles of polyurethane foam plastic products. For example, molds need to have sufficient pressure resistance, a smooth surface, designed draft angles and fillets, avoid dead ends for material flow, and set up exhaust holes of reasonable positions and sizes.
The following is a simple introduction to the above classifications.

1. Silicone molds

When the product has a complex pattern, has undercuts, and is large on the front and small on the back, and other molds cannot smoothly take out the product, we can only use silicone molds for production. Silicone molds are further divided into the following two types:
A. Resin soft mold. This is a type with a soft interior and a hard exterior. Inside the mold is a silicone inner mold. The outside is the same as a resin mold. Channel steel plus resin. Insert the silicone mold into the resin outer mold to form a soft interior and a hard exterior. The upper cover of the mold is also a resin mold.
B. Gypsum soft mold. Steel plate plus silicone. First make the silicone mold. Surround it with channel steel as a frame. Then pour in gypsum. Smooth the back. Use two steel plates to make the bottom and cover of the mold respectively. Weld adjustable hinges between the steel plates. Weld lock catches on the other three sides. Turn the silicone mold over and place it flat between the two steel plates. Adjust the hinges and lock catches.

When producing with this kind of soft mold, the following points should be noted:
A. When the mold is in production, there is little deformation. The waste edge at the joint with the upper mold is small, and there is not much material leakage. However, the cost will be relatively higher.
B. The upper and lower molds are both steel plates. The hinges are adjustable. The lower mold can be shared. Only the inner mold needs to be replaced. Inner molds of different sizes can be used. But the disadvantage is that both the upper and lower molds are steel plates. The sealing is poor. When the hinges are not adjusted properly, there will be material leakage. And the waste edge at the joint with the upper mold is thicker. The back of the product is not flat and needs to be processed such as grinding and planing the bottom.

2. Resin molds

This kind of mold is most widely used in the production of wood-like products. Resin molds have the characteristics of fast mold making speed, simple process, clear wood grain texture and vivid patterns when making molds. They can well meet the market needs and are conducive to timely launching of new products. In cases where the order quantity is moderate, the pattern is complex, there are no undercuts, and the delivery time is short, this mold is generally used for production.
Resin molds for making wood-like products are not easy to deform. There is almost no difference between the original mold and the finished product. If solid wood with deep and obvious wood grain such as ash is used as the original mold, then after painting the finished product, it can almost be indistinguishable from solid wood. The mold joint line of the product is small. There is also little waste edge from material leakage. The mold change is simple and the size stability is good.

3. Steel molds and aluminum molds

In cases where the order quantity is large and the product pattern is simple and there is no wood grain, this mold can be used for production.
Making steel molds and aluminum molds has a long cycle and high cost. And only products with simple patterns can be made. It also requires professional equipment and professional manufacturers to customize. In cases where there is no long-term stable order, it is not appropriate to open this mold. Moreover, steel and aluminum have fast heat conduction and high temperature. When producing in summer, the mold must be cooled down. Otherwise, there is a possibility of burning the surface.
As can seen from the above, different molds have their own characteristics, advantages, and disadvantages. By mastering these, we can “prescribe the right medicine according to the situation and occasion”, reduce production costs, improve production efficiency, and create more value.

4. Summarize the advantages and disadvantages of various molds for your reference.

Advantages of silicone molds: Short mold opening time, low cost, no requirements for patterns, simple mold making. Generally, those with a certain foundation can operate. A special paint is used as a release agent in the mold. Spray the oil directly into the silicone mold. After a few minutes, a thin film will form in the mold. Then inject PU material. This can eliminate the process of cleaning the release agent on the product surface. Disadvantages: Due to the strong foaming expansion force and the elasticity of silicone, the products made are often deformed and bent. The service life of the mold is short. Generally, it can be used about 60 to 80 times. Then, the silicone will stick to the mold and cannot be used. Damaged molds cannot be repaired.

Advantages of soft molds with upper and lower steel plates: Simple operation, convenient and fast. Disadvantages: High cost. The back of the product is not flat and requires secondary processing.

Advantages of resin molds: Not much requirement for patterns. Even if there are undercuts around the product, it can be made into three-part, four-part, five-part molds, etc. The product pattern is clear, the size stability is good. The mold making cycle is short. Generally, you can invite a master to work in the factory. Mold making can also be contracted out. Problems with the mold can be repaired in time. Disadvantages: The service life is generally about 1000 times. Aging and cracking of the mold may occur. After producing several hundred pieces, the joint line will become larger and the waste edge will thicken.

Advantages of steel molds and aluminum molds: Long service life, not easy to be damaged, good size stability. Disadvantages: High investment, requirements for order quantity. Stringent requirements for patterns. Long mold making cycle, high professionalism, and high difficulty in repairing molds.

We advise friends and bosses who are just starting a business. When you are doing small experiments, remember to buy materials such as backing materials and surface materials for making molds from regular mold material manufacturers. They will also teach you some operation methods. Don’t buy those so-called resins and gel coats from the market. Those materials are different from what we need. Otherwise, if you can’t make products after buying them, not only will you waste money, but it will also dampen our confidence in entering this industry.

I have been working at an R&D center and now I am a manufacturer of Polyurea coating materials and Spray machines since 2010 in China.
Pure & Hybrid Polyurea
Hand applying & Transparent polyurea.
Polyurea sealant(Cartridge) | Polyurethane.

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