DIY Network

Web Extras: Making a Vacuum Press Form and Silicone Mold From "Freeform Furniture" episode DFFF-209

Host Amy Devers demonstrates how to make a form using a vacuum press and how to make a silicone mold.

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Host Amy Devers shows you how to make a form using a vacuum press.

Making a Form Using a Vacuum Press

• Veneer is a great alternative to working with wood and gives woodworker's a lot more freedom when designing their pieces. After being out of favor for many years, veneer is finally coming back as one of the foremost materials in furniture design and high end interiors.

• No method is as versatile as the vacuum press system when creating forms with veneer. Through this system you can work with projects ranging from flat veneered panels to creating spiral staircases, because the bags used in the vacuum press can conform to practically any shape.

• To start creating your own form using a vacuum press, start with bending ply. This is a flexible wood that conforms to curves. Cut it down to a size that is a bit oversized for the final dimensions.

• Make sure to put a respirator and vinyl gloves on, then you can start mixing the adhesive. A two-part resin glue is best for this project. This two-part resin glue consists of resin and a hardener. Mix the two parts together for one minute and then spread an even coat on both pieces of bending ply with a brayer. It is great for bent laminations because when it cures the bond is a very rigid bond, which helps to reduce spring-back

• Line the ply up on the form and use an extra piece of bending ply with taped edges as a caul. Use strapping tape to adhere it to the form. This will keep it lined up while sliding it into a large vacuum bag. Seal the end of the bag with a plastic tube and a C-channel.

• Now simply flip the vacuum press on. As the vacuum sucks out the air, it bends the wood to the form you want. Let the tray dry overnight.

Host Amy Devers shows you how to create a silicone mold.

Making a Silicone Mold

• It is extremely important to be prepared when working with silicone molding. Make sure all necessary tools are ready and that you have safety equipment at hand.

• One of the great things about silicone is that it creates an exact replica of the original master. But this means that you need to make sure there are no imperfections in the original.

• It is important to allow air to exit during the casting process. One way to do this is to super glue thin wires to the edges where any air may end up getting trapped.

• Next you need to apply a release agent to the surfaces of the original. A wax release agent is recommended for the best results. A wax release agent will help the original separate from the mold without any sticking or tearing.

• Once the release agent has been applied, the mold is ready to be cast. Pour the silicone mold, and place the original or master copy, in the silicone mixture. Cast some closed cell foam inside the cushion to reduce the volume of silicone that was needed.

• Let it cure up while sitting on a perfectly level surface. Let is sit for the recommended time, or until the silicone has hardened. Use caution when extracting the master from the mold. Silicone is delicate and can be easily torn.

RESOURCES :

Festool
Website: www.festoolusa.com

Stanley Tools Product Group
Website: www.stanleytools.com

Lie-Nielsen Toolworks, Inc.
Website: www.lie-nielsen.com

Power Tools
Porter Cable Power Tools
Website: www.deltaportercable.com

Gladiator GarageWorks
Website: gladiatorgarageworks.com

Hand Tools
Garrett Wade Co., Inc.
Website: www.garrettwade.com

The Peck Tool Company
Website: www.pecktool.com

Biesemeyer
Website: www.biesemeyer.com

Saw Blades
Forrest Manufacturing Company
Website: www.vacupress.com

Jogensen Adjustable Clamp Company
Website: www.adjustableclamp.com

Adhesives, Abrasives and Safety Equipment
The 3M Company
Website: www.3m.com

Klein Tools
Website: www.kleintools.com

Power Tool Accessories
Woodcraft
Website: www.woodcraft.com

Ulmia GmbH
Website: www.ulmia.de

Shop Equipment
Eagle Manufacturing Company
Website: www.eagle-mfg.com

Delta Power Tools
Website: www.deltaportercable.com

WMH Tool Group
Website: www.whmtoolgroup.com

MacBeath Hardwood
Website: www.macbeath.com

Vacuum Pressing Systems, Inc.
Website: www.vacupress.com