Hi
i want to ask that how to make planes from moulds. I have the required moulds.
What are the chemicals (which on mixing expand and solidify) needed to make foamies ? And where can i get them ?
Thanks

From where did you get the moulds?

can you post some pics of the moulds.?

Self made. Inner surface polythene and HD  foam for shape.  the same method is used when making heli canopies at home. But the diffrence is in expanding foam we dont need a plug. Just the outer mould is needed.
Need help regarding chemicals

http://epsfoamprodotcom.sharepoint.com/Pages/ExpandedPolystyreneRawMaterialsResin.aspx
is this the thing i am looking for ?
Seniors  please help.

Am not sure about EPS foam ....
But you could definitely try PUF ( Poly Urethane Foam ) the one used for refrigeration . Available as two liquid form when mixed expands to form and takes the shape of the mould.
Regards
Dr Nayeem

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Thanks doc
i appreaciate the puf but why all foamy arf are made of eps .  if i couldnot know of  the chemical which expands eps beads then i will surely go for puf.

All RTF Fomies are not made in EPS but in EPE ...or a composite of foams ...coz of its resilience and fracture resistance ...
PUF is brittle in nature and not resistant to Impact.

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Well thanks doc
i feel comfortable with eps.
I figured out how to get the resin pallets but i dont know which activator (which expands pallets) and whats the process. I request more people to join and discuss opinions and share knowledge.

i read somewhere thart passing butane or pentane helps expanding the beads but how do they stick togather ??

I think you would need metallic moulds which is a costly affair. Sadly finding such Airworthy  raw material in India is very hard.

Okay
consider moulds sorted out. I already have moulds. The problem is chemicals which expand eps resin pallets.

try CF its the best and the most awesome material to make ur planes and since u already have the mould it should not be of any issue

Quote from: Tanmay.mathur on April 10, 2016, 10:36:25 PM
Okay
consider moulds sorted out. I already have moulds. The problem is chemicals which expand eps resin pallets.

So "Voice of Deaf" is a second account made by you?

My brother kunals secönd account

Cf is expensive stuff cant afford it.

really say cf is not that expensive if u know wht and where to buy

I would need CF cloth , and some resin , and accelerator.
And the weight must be in consideration.
And need some clever workmanship.


Someone experienced once told me superheated stem is passed through the pallets and then they expand ..
This method is way out of my reach ..
So if there is any other way then good
Else i am going towards SPADS

@tanmay.mathur
Before passing superheated steam, you may like to check what 'pallets' are.
Doubt if they expand...

Come on. You can do better than this.

And why these multiple accounts?

(You may remember speaking to me a year or two ago...)

@tanmay.mathur
Jokes apart, moulding is too complicated, as a male plug (wooden?) has to be made first, then the female mould made in fibreglass. Then a supplier of thermocol pellets has to be found.

An easier alternative is to carve/sand the part in depron or thermocol and cover with fine glass cloth and finish cure epoxy.

Picture shows a chuck glider wing made using a disposable dinner plate (about 1-1.5mm thick) and a canopy carved, sanded and hollowed using 2" thick thermocol.

Covered with 18gm/sqm glass cloth (thinner than a handkerchief) using 20 minute finish cure epoxy.
I got the glass and epoxy a few years ago from adiboy, who used to get stuff from Hobbyking.

Not sure if any LHS has this epoxy (which is quite thin), but i remember some LHS had the superfine glass. Will let you know if i am able to locate.

Best of luck with your experiments.

I did not read all the replies above. I apologize if i am repeating someone's post.

I researched a little bit on this, but did not pursue because of lack of funding and time.

1. You can try Polyurethane Foam Spray. PUF 40. it is rigid foam. The foam expands automatically after spraying. Easy to work with.
Link: http://www.anabond.in/aerosol-products.html   (search for "polyurethane foam spray" in the page)
Also available in amazon.in

2.Or use two part polyurethane rigid foam. I talked to the staff, the minimum quantity to buy is 1 liter, each part. Need to mix two parts on certain ratio.
Link: https://www.tradeindia.com/fp2286762/Liquid-Polyurethane-Foam.html

In my guess, both these foam will work for us. light weight and rigid.And can be easily cut and sanded to required shape. Both the options will not cost more than 2000 Rupees.

@tanmay.mathur
Read you post again and realised you have already made a mould, and you only need pellets.
Or foam.
See if you can get this in India.
A friend got it for me from Saudi Arabia.
My can is jammed as I didn't have acetone to clean the nozzle. Solvents don't work after it dries.

Meanwhile I'm going to look at ajay sarwan's suggestions in reply #20

I thoroughly apologize for my late reply .,
Sorry (college guy)
I am grateful for your super informative inputs sir @K K Iyer
And ajay sarvan sir , i do. Accept the fact that using a polyurethane foaming solution is way easier than fiddling with EPO or EPS . And their  other affairs like steam and chems ......
Although i get a reference nàme " Soudal " foam , which is with AhmedT sir.
Please correct me if i am wrong.
I found some suppliers of the two part foam+ activator  solutions.
I must dig a little , and get some samples to start up.
Then i will think up in quality moulds .
Currently the moulds itself is made up of HD FOAM. With surfaces covered in polyethene  .
Lets see how far i can go.
Thanks again for your efforts.