Frequently Asked Questions - Moulds

Please find following our list of frequently asked questions (FAQ's) regarding our moulds and mould making techniques.

FAQ Categories: Moulds | Mould Making Techniques | Ordering and Payment System | Shipping and Postage

Moulds

Q: How do we make our moulds?
A: We often get asked this question as neither Joan, Stef, Adam, or myself are what you could call a sculpturing genius. It took us over 12 months working hard to modify the industrial production methods that we use to make hobby and professional style vacuum formed moulds.

The usual production method for making this type of mould, is to start off by sculpting your original in potters clay or one of the newer air hardening or oven hardening clays. Then making a plaster or RTV rubber mould of the finished sculpture. A casting of this mould is then made in either aluminium resin or Drystone or Hydrostone gypsum and mounted up for future vacuum forming. This is a skilled process that can take weeks to finish.
By taking small steps and modifying as you go you can achieve results that are not dissimilar to the work of a professional sculptor. Car bodies are set up for manufacturing by producing models and modifying as you go till a final design is approved for manufacture.

We sculpt a working model, make a vacuum formed mould, cast an intermediate model, refine it, alter it slightly, make another mould refine it again until we are satisfied with the result and then and only then do we make our production model for future vacuum forming.

We also work from sketches, drawings and photographs of proposed moulds using a modified industrial CAD/CAM program. It cost some tens of thousands of dollars and we live in hopes that one day it may begin to pay for itself. We worked on it for some 12 months before opening for business to adjust it to our proposed method of production and it is only now beginning to show that our time was not wasted.

Basically we take a 2D flat sketch, clean it up, modify it and give it a 3D appearance with the tools built in to the program. Then we rastorise or vectorise it, calculate a machining path and then send it to our CNC for final processing before vacuum forming-and if this all sounds a bit over the top, it is!

If you look closely at our latest moulds you will see a much greater degree of detail than in the usual imported moulds. We are continually raising our production standards and we hope it is beginning to show. One of our latest moulds took 48 hours machining time for a job that normally would take 4 to 6 hours. And this for a hobby mould! Job satisfaction is what it is, at least that is what you call it when you can't justify it cost wise.

Q: Are you ever out of stock of one of your products?
A: Except for a limited showroom display stock, we manufacture all of our moulds after receipt of your order so we should never be in a position not to be able to supply you.
The Supercast latex range however is imported from England and many of the mould making materials are imported and could be out of stock for limited periods. We remove any item O/S from our website on a daily basis. We will contact you by email to see if you would like the item placed on backorder.

Q: Do you have a showroom?
A: We occupy industrial factory premises at 22A Hearne Street Mortdale and have a small area set aside for display and direct sale from 8:30am - 4:30pmpm Monday to Friday. You are welcome to visit us at any time.

Q: Do you have a catalogue?
A: The daily development of new moulds prevents us from issuing an up to date printed catalogue so we have opted for keeping our official online store www.aldaxmoulds.com.au, our eBay store http://stores.ebay.com.au/aldax-moulds and our website www.aldax.com.au updated together with our monthly newsletter. You can receive the free newsletter by sending us your name and email address to newsletter@aldax.com.au.

Q: Are the moulds reusable?
A: Treated with care our vacuum formed moulds and latex moulds will last for years and produce many castings. If latex is exposed to continuous heat and sunlight, the mould may only last for 12 months before starting to deteriorate.

Q: Do you cast moulds?
A: Yes, please email us at aldax@bigpond.com.au for more information.

Q: Are your moulds suitable for fetes or plaster parties?
A: A very large number of our hobby moulds are used just for this purpose. Many fetes use our moulds and add a few new ones each year to add variety. Get a volunteer, usually a retired person to pour the moulds and the rest is pure profit. A wonderful fund raiser and immensely popular with the children.

Q: What are latex moulds and what are they used for?
A: Latex rubber moulds produce a 3D object rather than a plaque or flat backed object such as is produced using vacuum formed plastic moulds.
They are much more difficult and labour intensive to produce and consequently are much more expensive than plastic moulds. The plaster is poured into the latex mould and when hard the mould is removed by pulling off much the same way you would remove a sock from your foot.
We have available a kit, complete with everything you need to make latex moulds available on our eBay Store.

Q: What and where can I sell my finished plaster and concrete ornaments?
A: This proved to be too big and important a subject to just answer briefly - so we compiled a book for concrete that is listed on our website and are preparing a similar publication for plaster - which will be listed when completed.
The idea was "We tell all" all the trade secrets from making the product and decorating and then making money from all your good work.
Those who take the time and labour to become professionals in this field are making good money from their efforts. It's one of the fields where "Big Business" cannot compete - the local producer has all the advantage. No freight costs, low material costs and so very high profit margins.
We intend to provide all the information we can to help the "start up" businesses in this field. Watch our newsletter and websites. For our free newsletter email us at newsletter@aldax.com.au and leave your name and email address or complete the easy signup form here.

Mould Making Techniques

Q: How many pieces can I pour from my mould?
A: With vacuum formed moulds this greatly depends on the flexibility required and the thickness and type of plastic used. The thicker the plastic the longer the life. For our hobby moulds we use 0.5 to 1.00mm plastic while for our professional concrete moulds we use thicker ABS. Even our thinnest plastic hobby moulds will last for years and with care produce many dozens of casts. Our production moulds will yield 100's of castings. We have yet to wear one out.

Q: Can anything be transformed into a mould?
A: With our revolutionary new 3D Imaging Software and CNC Sutting Device, we can transform and replicate any shape in to a beautiful mould.

Q: What type of plaster do you use and where do you get it?
A: There are many different types of plaster made from the coarse builder's Plaster of Paris to pottery and dental plasters. All have their uses. The plaster we recommend and use is called casting plaster and is manufactured by Boral and C.S.R
This plaster has an ingredient added that hardens the surface and gives a beautiful finish. The risk of chipping is reduced and the surface is ideal for decorating with hobby acrylic paints.
It is usually available from local plasterboard suppliers and if they don't stock it, they can order it in for you. We can supply this idea by courier - but freight costs are such, local supply is the preferred. Contact us for information on how to mix and pour casting plaster.

Q: What do you use to decorate plaster and decorate concrete ornaments?
A: For plaster we recommend sealing with an acrylic sealer either spray or brushed and using hobby acrylic paints to decorate - followed by another spray of the acrylic sealer. Concrete is usually antiqued by brushing the finished ornament with a metallic oxide mixed with water and then wiping off the colour on all the raised portions with cloth to leave the colour in the recesses.
Further information is available on our new website www.moulds4concrete.com.au.

Ordering and Payment System

Q: What types of payment do you accept?
A: Credit cards including Master card and Visa - Pay Pal - Personal Cheque - Money Orders - or direct debit into our bank account which is Westpac Rockdale NSW BSB - 032 057 Account Number 239801.

If you are uncomfortable with having your credit card details online; (our site is secure with 128 bit encryption) you may phone us during business hours 8:30am - 4:30pm Monday to Friday on 02/9533 9555 or internationally 0061 2 9533 9555, making sure you include your name and the delivery address with quantity and stock number for the item ordered.
Payment details should include your full card number, expiry date and name on card.

You can also fax your order to 02 9533 9955

If ordering by email Do Not leave your card details as it's not secure.

Q: How long does it take to receive my order?
A: We endeavour to ship all orders within 24 hours of receipt of your payment. It takes 3-4 days for Australian shipment to arrive. 5-10 days for the UK and USA. Most other countries within 14 days.

Q: Do you offer quantity pricing?
A: You are buying direct from the manufacturer. There is no wholesaler involved. Our mould prices are trade prices less the following overriding discounts for quantity buyers.
10-19 moulds Less and additional 5% discount
20-29 - 10% discount
30-39 - 12% discount
40-49 - 15% discount
50 & over - 20% discount

Shipping and Postage

Q: Do you ship your goods Worldwide?
A: We endeavour to give you as close a freight estimate as possible with each item or range of items for standard post. Some Resins in the fiberglass mould making section cannot be sent by post and require courier delivery.

Q: Do you ship worldwide?
A: Yes, we post to all countries worldwide. Our hobby moulds are light and cost little to post. Please email for postage rates.