Step 5: Preparing Mold and Casting Wax | How To Make a Breakaway Glass Bottle Prop (2024)

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Step 5: Preparing Mold and Casting Wax | How To Make a Breakaway Glass Bottle Prop? ›

Step 5: Preparing Mold and Casting Wax

In order to make a mold for casting, add silica, plaster, and water in equal proportion. Silica has a high refractory and plaster gives the support. Mix the mixture together until it gains consistency similar to heavy cream. Build a temporary cover around the wax model to secure the mold.

You create sugar glass by melting ingredients in a pot over a stove until it reaches a certain temperature and all the moisture has been cooked out. You then carefully pour this molten mix into a negative mold of the object you wish to cast. In this case a rubber bottle mold that you have made and properly prepared.

Dating as far back as the Egyptian period, glass casting is a technique where molten glass is poured into a mold, then allowed to solidify. This process creates a solid piece of glass in the shape of whatever mold was used.

An investment casting wax composition containing 35% of a copolymer of Alpha -methylstyrene and vinyl toluene, 45% of paraffin of 70*C. melting point, 10% carnauba wax, 5% microcrystalline wax of 90*C. melting point and 5% microcrystalline wax of 85*C.

Making a breakaway glass bottle starts with making a silicone rubber mold of a real bottle. The rubber mold can then be used for casting SMASH! ® Plastic to make the breakaway glass bottle.

Sugar glass.

This is the traditional type of stunt glass we discussed above. By cooking a mixture of sugar, corn syrup and water to a temperature of 150°C, you can create a hard candy that cracks and breaks just like real glass.

Pour the sugar into a small pan on a stove over low heat. Stir continuously until the sugar melts (takes a while). If you have a candy thermometer, remove from heat at the hard crack stage (clear glass). If the sugar is heated just past the hard crack stage it will turn amber (colored translucent glass).

Make sure the pan is level. The thinner you spread it out the thinner the glass will be. Then wait for it to set. This usually takes an hour or two.

What are glass casting molds made of? ›

Kiln casting involves the preparation of a mould which is often made of a mixture of plaster and refractory materials such as silica. A model can be made from any solid material, such as wax, wood, or metal, and after taking a cast of the model (a process called investment) the model is removed from the mould.

Plaster/Silica

A mixture of 50% pottery plaster and 50% silica flour (also called flint) makes an exceptional and low-cost material for casting and fusing molds. It's very low cost, easy to use and picks up fine detail.

Molds for the casting process consist of two halves. Casting molds are usually formed from gray cast iron because it has about the best thermal fatigue resistance, but other materials include steel, bronze, and graphite. These metals are chosen because of their resistance to erosion and thermal fatigue.

Molds are made out of materials that can withstand high firing temperatures in the kiln. Most molds are made of ceramic clay or stainless steel.