There are a number of ways to produce the tooling/molds for this particular application.
1. Take an existing ceramic tile and vacuum form over the tile. Providing the tile has a good texture, there should be enough relief to allow the vacuum to draw over the tile in order to get decent definition. Ideally the molds need to have small 1mm – 1.5mm vacuum holes drilled in all the recesses. Then use the vacuum-forming to pour in liquid epoxy resin to create the production tool.
Figure 1. Existing ceramic tile beneath vacuum-forming.
2. Take the vacuum forming and turn it upside down. Then mix up an epoxy resin with an aluminium powder filler and pour it into the vacuum-forming. Make sure to apply a release agent to the vacuum-forming to help with the mold release when the resin has cured.
Figure 2. Pour liquid epoxy resin with an aluminium powder filler into the vacuum-forming. **Please note that silicon sheet cannot be vacuum-formed.
3. When the resin has cured, remove it from the vacuum-forming. Depending on the resin used, there may be the need to post-cure the resin in an oven. This will stop the resin from becoming too flexible as the mold gets hot during the production of vacuum-formings.
4. Once the mold has been fully cured, drill 1mm – 1.5mm vacuum holes in the recesses and corners of the mold.
5. To obtain the maximum detail from the ceramic tiles, cast a liquid silicone rubber over the tile. When the silicone has set, pour the epoxy resin into the silicone rubber mold to create the production mold. Be certain to place the silicone mold on a flat surface and support it all around the outer edges with wood or steel so that it remains square while the epoxy resin goes hard.
For more about Formech vacuum formers and the vacuum-forming process, call, email, or visit our website now.
Excellence in service, support and production have made Formech a market stalwart who can boast over 30 years of business building with consistent product innovation. Over 8000 customers worldwide from industry giants to renowned design and prototyping companies to prestigious engineering and design schools and more, have chosen Formech. Contact us today, you’ll be in great company.
Formech Inc. 