Products used in this How To:

• Alumilite Regular
• Filler (Microballoons used here)
• Mold
• Popsicle Stick
• Cups

Casting w/ Alumilite Fillers

Dry Fillers can be mixed into Alumilite to add different characteristics and to extend the volume of Alumilite Casting Resin. Any dry filler can be added into the Alumilite, we offer 3 different fillers (microballoons, aluminum powder, porcelain). You can add up to 100% by volume. Microballoons add space and buoyancy to your cast part. If you are looking to make your part lighter, have it float in water, or to use significantly less resin try using mircoballoons. Aluminum Powder is used to add weight, increase heat resistance, and to help dissipate unwanted heat. The Aluminum Powder will turn the Alumilite casting gray. To bring the Aluminum reflection out of the cast piece, simply sand the casting with a fine sandpaper. Porcelain Powder is used with Alumilite White Casting Resin to achieve cold cast porcelain. It gives the user the look, feel, and texture of a porcelain casting. Use the porcelain in conjunction with the flesh tone dyes to duplicate one of a kind dolls and sculptures.


The first step is to gather the materials that are needed. Alumilite Casting Resin, a popsicle stick, cups, filler (we are using microballoons), and your mold.


Next measure equal amounts of both sides of Alumilite's Casting Resin. Then measure equal amounts of the microballoons for each side of the resin. Add the filler to both sides of the resin before mixing the two sides of resin together, this will provide you with a better mix and more consistant results. Here, we are going to add 100% of microballoons (by volume) to our resin. In otherwords, for every ounce of resin used, one ounce of microballoons are added.


Mix equal amounts of each side of the resin with the same amount of microballoons (the 'B' side is being shown in the picture). Repeat this process for the 'A' side.


Stir in the microballons until uniform color is reached. Since you are mixing a substance into the Alumilite, keep in mind that you are also thickening the Alumilite. When you eventually mix the two sides together and pour the microballoon filled resin into your mold, the consistancy or viscosity will be a little thicker.


Pour both sides of the Alumilite Casting Resin with microballoons into a cup.


Stir until uniform color is reached (about 25 seconds).


Slowly pour resin into your mold. Remember, you can tip the mold a little while you pour to help fill in any undercuts and reduce the chance of air bubbles. Alumilite Regular has a 90 second open time and a demold time of approximately 5 minutes.


Once the Alumilite Regular has set up, demold your cast piece. Your cast replica will have the exact detail of your original with the characteristics of the filler you used. This entire process took less than 7 minutes.