How To Make Custom Foam Storage Inserts - Foam Casting Tutorial

[@rolfathan]

Man. It's a lot of effort buy I cannot deny how nice it looks with those super soft edges. Very nice work.

[@smoothon]

Haha, yeah, the struggle is real, but it's worth it for the nice look, right? Thanks for watching and don't forget to subscribe if you haven't already.

[@literate-aside]

Great video. For me, Kaizen and similar products make a lot more sense. They’re quick, easy, and the removed material can be glued down and a new insert made.

[@bablenacklemoron903]

10:32 Great. Thanks Smooth-On, now I am craving 3 beers.

[@BMCOmotors]

I'd like to see how is built some kind of motorcycle seat like the acerbis x-seat!, Great Video!

[@arcuchi]

Fantastic, is it possible to do exactly the same but with EVA foam? I would lime to make foam inserts for harmonica cases

[@UncleDiddles]

Id like to see this used to make custom foam inserts for a pelican case

[@JohnniePokemonNj]

I found this video looking to do it for a pelican case I want to use it for my refrigeration gauges to protect them. I am worried that the foam that comes in the case will break down and get into my gauge’s

[@markrainey3268]

I would like to see a take on customise a shakespeare 2018 beta box for my fly reels and spare spools and needs to be closed cell foam because the foam will get wet.... great video

[@JOEGGGJOE]

Great video. Back pressure home cut out is a great idea. I've dealt with air pockets at times with expansion foam.

[@AmorCNCLaser]

Unbelievable! I though it is EVA foam, but it is for box. usful video!

[@smoothon]

Glad you liked it!

[@8liontv]

What is the can he used to pump alcohol out of the top called at 12:32 ?

[@8liontv]

Found it - they're called JustRite Plunger Can sold by ULine

[@smoothon]

Correct, these are called JustRite Plunger Cans sold by ULine

[@jammywesty91]

Hi guys. Do you have a product suitable for making that open cell foam showcased at 0:39?

[@smoothon]

Hi there! This is a good question for our tech support team, can you send them a ticket here? www.smooth-on.com/support/ticket/add/agree/ Thanks for watching!

[@bobcatt2294]

There exist closed cell foam sheets in various densities that are widely available - what you have stated at: 0:39 is incorrect.

[@alessandrocernuzzi]

Amazing! I'm totally going to mould this foam for my camera and telescope cases :)

[@wirewrappedforsale]

Wow great ideas and info. Rock On!

[@mleeman01]

Firearms are not particularly vulnerable to heat or pressure. Can I wrap them in plastic wrap and cast directly?

[@smoothon]

The risk of foam adhering to the piece would be high, would recommend testing the process first.

[@TheNewton]

+Michael Leeman I'm looking for a repeatable solution to a similar problem but with firearms consider using scrap kydex and making as tight a form as you can and using that kydex as a molding buck. Though i'd double check the curing temperature first and the kydex's specs' which can vary with quality . And keep in mind kydex softens well before the melting point too.

[@jayswan7598]

I would like to make domed decals for my daughter’s softball team helmets with their numbers and possibly the school’s mascot. Or please let us know what materials works best for custom domed decals. One thing I have noticed with store bought domed decals are that the color under the domed flexible material fade with time in the harsh sun. Is there a UV additive that can be added to protect the original printed colors? The base material will likely be printed on an ink jet printer with either photo paper or regular bond paper. One final thought, will the printed paper need to be sealed with something prior to adding the domed material, which you suggest, to keep the colors from running? Can you do that as a project as I know a lot of parents would love to do this for family projects? Thanks a bunch.

[@smoothon]

For this application we would recommend taking a look at our EpoxAcast 690 UV resistant epoxy resin: www.smooth-on.com/products/epoxacast-690/

[@wojomojo]

Will there be an offgassing from the foam over time, that may be harmful to optic and electronic?

[@KowboyUSA]

Good question.

[@smoothon]

Once the material is fully cured, there is nothing outgassing from the system.

[@rescuemethod]

can this be used for a shoe footbed? I'd like to test and adjust how soft and cushioned it is, how much rebound and how is the compression set over time. Also, can a textile be cemented to the surface? is heat/pressure needed?

[@smoothon]

Can you send us a tech ticket? Our team can help you - www.smooth-on.com/support/ticket/add/agree/

[@KD4BAW]

Do you have a video for making one for hand tools in your tool cabinet? Specifically sockets and wrenches and such tools? If you do please send me the link!!! GREAT VIDEO!!!!!

[@smoothon]

Not as of yet, but we will forward this request to our video department. Thank you for watching!

[@benhuber8209]

This is a great video!!! I found it while looking for a way to make tool box inserts for wrenches, pliers ect. Would this foam be the best for that? Or would a more rigid foam be better since it's not delicate equipment? Thanks for the video! You gained a subscriber because of it!!!!!!

[@MNNICEGaming]

Ben Huber same here did it work mate ?

[@veganwilliamdotyfreshour3665]

Professional!

[@smoothon]

Thank you!

[@elvenaesthetic6477]

Great video, super helpful, as aways.

[@KRGraphicsCG]

I wonder how to use this for custom helmet foam (non PPE).

[@smoothon]

Can you send us a tech ticket? Our team can help you - www.smooth-on.com/support/ticket/add/agree/

[@benstill571]

Beautiful work, expensive but so nice. How do you remove the excess mold release from the molded foam before bringing it in contact with sensitive parts?

[@miloradmedunic6202]

Look at 14:20

[@miloradmedunic6202]

If you make a silicone mold... no release is necessary!

[@toddgregory2962]

I’d like to see an Archery Target be made from your product.

[@smoothon]

I will add it to the project list. We do have a video on repairing an archery target if you haven't seen that one. kzbin.info/www/bejne/fJLFqYCgqceYeLs

[@kevinyaeger9822]

Is this mold repeatable? Can you use it multiple times without having to reapply a release agent or fix the clay?

[@smoothon]

Yes you could.

[@gazalapathan6274]

Hi there, the mold for the camera and lenses looks amazing! I want to create tall, light weight indoor planters for my home using using two sonotubes - 10 inch & 8 inch diameters to create a hollow tall cylinder. Height 36 inches. Thinking of using Foam -iT X self expanding foam to pour in between these sonotubes to create this planter. I plan to suspend an 8 inch wide planter on the top rim of this cylinder. I am not worried about the external looks - can paint it. Will this cylinder be strong enough to stand on its own and hold the weight of the potted plants? If not, what reinforcements could be used to hold the shape? Quite a few friends are looking for creating their own tall planters at home, as anything on the market is super expensive - especially if we want a few around the house. If you have a better plan to create this, could you please make a video demonstrating these? Thank you so much.

[@smoothon]

Can you send us a tech ticket? Our team can help you - www.smooth-on.com/support/ticket/add/agree/

[@jessejaviangel]

Great job!

[@smoothon]

Thank you for watching!

[@charliean9237]

Inspiring! I’m looking for a way to cast a foam painting/photo frame. :-)

[@MerinaAmos]

How could I use this technique for music instrument cases? Octoban drums specifically.

[@smoothon]

Can you send us a tech ticket? Our team can help you - www.smooth-on.com/support/ticket/add/agree/

[@dreamcatcherdb]

I stumbled upon this video while looking for solutions to foam fill the flimsy thermoformed plastic organizer shadow trays that many tools come with. While I am not sure this particular product would work for my application, I would be interested to see a video showing how to foam fill such trays and how to create custom trays for complex shaped tools. I have seen some videos pertaining to making custom tool trays but they tend to deal with expanding spray foam. Some wrap plastic around tools but that tends to allow the foam to wrap too tightly around the tool. I have even seen one that used cotton t-shirt material as a barrier but the foam leaked through the material. I would like to see what solutions you may have. Thanks for the videos.

[@smoothon]

Can you send us a tech ticket? Our team can help you - www.smooth-on.com/support/ticket/add/agree/

[@butchc7650]

Could you use this product to make auto seat cushions or is it too dense/or not? Also what is its longevity expectancy?

[@smoothon]

Many of our customers use this material for custom cushion applications. Longevity depends on usage scenario and type of covering applied to the cushion.

[@Rumination_Vertex]

What about for recording panels of foam? Do they use the same kind of foam for that? The texture fells different than other foams I've seen so just checking. Thanks

[@smoothon]

Tony, generally those are made using open-cell foam. FlexFoam-iT! foams are closed cell.

[@KowboyUSA]

Didn't know this product was available. I'm intrigued.

[@TheNewton]

Are there any tutorials on making tighter fitting molds of equipment without general placeholders, like maybe how they make f1 racing seats with vacuum bagging ?

[@smoothon]

Thanks for watching! We have a tutorial which may help - kzbin.info/www/bejne/nGiloJp4d5WBf5o

[@TheNewton]

Thanks i did watch that workflow, not sure that's good for sensitive parts or one offs. Don't know enough about molding so probably what i think i want doesn't exist for a reason. Thanks again.

[@boxsterman77]

How do you go about making the actual shape of irregularly shaped items such as pliers, wrenches, hammers etc.?

[@smoothon]

You could try to use the original tools, but would need to wrap in plastic wrap and apply sufficient release such as Sonite Wax.

[@TheBillPayingHobbyists]

How does it hold up for weapons?

[@smoothon]

For specific information on using Smooth-On materials for weapons, please contact Smooth-On technical support for guidance. You can reach them at 1-610-252-5800 or visit the Smooth-On Technical Support Page for more assistance.

[@johnroyal4913]

6# pour foam mold that can be reused for something like car interior parts.

[@MsPoliteRants]

Do you have a product for making a custom foam enclosure to ship and store handmade delicate statues? Since the pressure of this foam is so high, i couldnt just put my statue in a bag and box and fill the box around it... so, what would you recommend?

[@smoothon]

Can you send us a tech ticket? Our team can help you - www.smooth-on.com/support/ticket/add/agree/

[@dreamcatcherdb]

I used to work in a factory that would use two part expanding spray foam sprayed into cheap can liners (garbage bags) to pack around delicate equipment before shipping.

[@TiborFuto]

Is there a flexible foam that is ESD safe?

[@smoothon]

We don't test for electro-static resistance.

[@jimsutton2243]

I'd really like to see a video on a similar use to create CLAM SHELL inserts for a PELICAN case around a PARAMOTOR where you might need to plastic bag the paramotor as you can't use 2831 Release on the equipment. Issue: 1) How do you make a clam shell inserts? 2) How do you make it inside the Pelican Case? - Or would you create a melamine box of the dimensions of one side of the PELICAN case?

[@mainstay.]

I woulkd like to make a foam sword, would this material be suitable?

[@smoothon]

It would be, though some prefer a firmer foam such as Flex Foam iT! 25. WE have a tutorial for making a foam sword here: www.smooth-on.com/tutorials/prop-movie-fantasy-swords-flexible-foam/

[@VARocketry]

Can make a video showing how to make a clamshell insert or a PELICAN case insert for PARAMOTOR equipment with lots of undercuts or where Release 2831 can't be applied - likely using a plastic bag around the equipment. How do you mate up the clamshell halves? Or, how to use a pressure plate in this application? PS. I'll drive to your PA location with the Pelican case and paramotor to assist you.

[@smoothon]

Thanks VARocketry, this is a great idea, and we will forward this to management! Thanks for watching and don't forget to subscribe!

[@VARocketry]

I really appreciate the high quality videos, been watching for years.

[@christiandanzig2283]

Why cleaning tools with "denatured" Alcohol? Is that also true for plat Silicones?

[@kcirei]

I'm an avid Table Top War Gamer we use Miniatures of various sizes. Would this be a good choice of material to make inserts for caring cases, or would another one of your products work better?

[@TheZahnputz]

get pre-foamed sheets and contact cement. cut out the spaces with a sharp knife and glue a uncut layer of foam sheet on the back.

[@matthewjackson4962]

Is there a company that will work with you to make custom packing using this foam tech?

[@AndrewHelgeCox]

How much does it cost to make one of these?

[@smoothon]

It would depend on the dimensions. Once you have those, you can use our estimator here: www.smooth-on.com/support/calculators/#casting

[@cbrockbishop1566]

Im interested in this stuff, but I don't understand why you used cardboard tubes and filled them with modelling clay for the cylinder shaped pockets? Why not just use a plastic cup or a tin can?

[@butchc7650]

Tks

[@michaeluncapher83]

Is it possible to 3D print your gear and then use that 3D print rather than the actual body of the camera?

[@gregistopal]

Obviously yes

[@tacsystems5621]

Could you use this for tools?

[@smoothon]

Certainly. Thanks for watching!

[@jrlee6]

How about making a gun case insert

[@smoothon]

Great idea! You should be able to use the same technique to make a foam gun case insert.

[@bobcatt2294]

Your method although great, it is labor intensive.

[@LaserGadgets]

Are you kidding or insanely lazy? Oo

[@vanhooren1]

is there a retardent for the foam ?

[@smoothon]

There is not an additive for slowing the foam.

[@jrlee6]

Yeah but unless you have blue or red guns to use as mould plugs you would have to wrap your gun in something basically a condom so your gun won’t get stuck and ruined. At least if you have a blue or red gun you can clay it down to a board and put mould release on it. But I have a few that are not a available in a blue or red. So unless I want to go through another process to make my own dummy gun.

[@gregoryperrine948]

yes I have a idea then you might be able to make I make a lot of money off of them my name is Greg and I want to buy some KitchenAid attachments but my problem is is they don't have a carrying case and I think your idea of what the expanding foam would be ideal for my idea I'm looking for a have been looking for a case much like you just made with the expanding foam for KitchenAid stand mixer attachment heads such as the 5-piece pasta maker attachments for stand mixer I was catching Aid has as the box that comes on which is very flimsy and people spend about 5 $600 on these attachments I didn't KitchenAid should have came up with a better idea on how to package up I mean like there are sheet cutter spiralizer and scale shifter attachment they all come in no keepsake boxes so to speak storage cases but the pasta has for some reason don't so if you can make something for the pasta had attachments he probably make a lot of money

[@bobkeller8383]

A person in a wetsuit as the mold

[@TheZahnputz]

as much as i like smooth on and their range of products, this video portrays an unnecessary effort and waste production. for this kind of inserts the use of laser- (or hand-) cut foam sheets is cheaper, faster and a LOT better for the environment (wood, plastic cups, toxic chemicals). just saying.

[@dreded7961]

and where do i get this laser cut foam?

[@TheZahnputz]

@@dreded7961 I got the foam sheets from a foam supplier (polyurethane foam for furniture and matresses). the cutting can be done in some copyshops or by similar advertisement suppliers that have the mashines. you'd have to bring the material and a technical drawing.

[@TheZahnputz]

@@dreded7961 *polyethylene foam kzbin.info/www/bejne/l2GWf5uhfN-MgZI seems to be the choice for laser cutting (i cut mine by hand)