Casting Alumilite White Pen Blanks and Dyeing The Resin Using A Pressure Pot

This is the first video totally dedicated to pouring resin pen blanks. I use Alumilite, so I wanted to show my process for pouring pen blanks in a mold. I also show what to expect when using Alumilite White and adding dyes.
In this pour, I used violet dye and added it in swirls to the plain white Alumilite. In future videos, I'll be covering Alumilite Clear casting, plus mixing other materials like wood and plastic into your casting.

[@topflight2358]

what scale you have or recommend , got 1 on ebay and takes it a min to get to weight, i go over the amount to resin , then have to pour out, i must need a scale that gives fast measurement ???

[@Hmatza1]

what is the psi pressure pot for casting resin for label casting

[@markgoerdt417]

How do you get plain ( non pearlescent) colors

[@315retro]

Have you tried pearlescent mica powders in this white alumilite? I'm wondering how the pearl color looks vs the clear I'm used to.

[@kmassing]

Hi Zac. Great video, and thanks for sharing your experience. I've used Amazing Clear Cast and am ready to use the white. I am a bit confused about measuring by volume or weight, Alumilite videos say to measure the white by volume and not weight. you didn't seem to have any issues weighing. Also, a video Curtis did cured in the pressure pot for 20-30 minutes then cutting into blanks, have you demolded and turned in so short a time? I'm not doubting your expertise, just confused and don't want to waste a batch of white.

[@morganfisher1946]

Thanks Zac` I think I`m going to try Poly. I know you mentioned you didn`t mess with it. The fact I have to use it indoors because I cannot get my shop warm enough makes me question using it, plus the odor, but it is about 50% cheaper. I`m doing a lot of experimenting so I don`t want to spend the money for alumilite. I guess it works about the same but not as easy. Thanks for all the videos, they do help.

[@airdakota]

Thanks. There's a HF not for from me and I have a coupon.

[@colinchalmers1099]

Excellent video Zac, cheers Colin.

[@ZacHiggins]

Thanks Colin, more vids to come

[@morganfisher1946]

Thanks Zac. I just made my first casting for pen blanks. Worked out quit nice. I can see it can be pretty expensive with a lot of waste. I think I will have to try casting around the tube to save money. The only problem it kind of limits you to what you use for coloring. I`ll have to start ordering in greater volume to help with the cost. I hope my wife thinks it is worth it to keep me out of her hair. I got my alumilite from amazon, is there a better supplier out there? Thanks for the video keep up the good work.

[@ZacHiggins]

+Morgan Fisher That's great to hear! I'm glad you're having fun with casting. You're right, it does cost a bit of money but buying in larger volumes does save some dough. I would recommend buying Alumilite directly from their website. The problem with buying resins from craft stores or on Amazon is you don't know how long it sat on the shelf, and there is a limited shelf life.

[@arielvidela8432]

I like to combine resin with wood but the resin I use is too thick to work with. I noticed yours is more of a liquid consistency. What resin do you recommend? Thanks

[@ZacHiggins]

Hey Ariel, I used Alumilite Clear resin for this project which is a faster setting resin and requires a pressure pot to remove the air bubbles. If you're looking for a slow setting resin, I'd go with Liquid Diamonds epoxy. I have links to both of those on my "tools I use" page on my website: nvwoodwerks.com/tools/

[@powertekusa]

Are you using an air compressor for the pressure pot or a vacuum pump ? If you are using an air compressor, I guess I don't understand how you would remove the air bubbles ? Did you have to modify the pressure pot ?

[@ZacHiggins]

Yep, it's hooked to an air compressor. It pressurizes it, which pushes the bubbles out. I'm not entirely sure what the physics are in the situation, but that's what Alumilite recommends. Vacuum can be used as well, but I haven't tried that. I did modify the pressure pot, and I just did a video on setting it up: kzbin.info/www/bejne/rICUpHdpp9uNmqM

[@chrsjstls]

Zac Higgins just a note on what happens with the bubbles, I'm sure that they are still there but by adding pressure you are just making them a lot smaller so they appear to be gone, basically the gasses that make the bubbles are getting compressed to a smaller size.

[@TurningRound]

Great video, Great intro, I have played with this process 3 or 4 times at our pen club meetings it's fun stuff. It's next on my list of things to do, after all those other things on the list.

[@ZacHiggins]

Thanks Ian. Can't wait to see what you make when you start getting into casting. Watch out though, it's a rabbit hole! You may get sucked in like I did.

[@TurningRound]

Zac Higgins Do you have a good source for Alumilite? I have been looking and have some good ideas for some pen blanks.

[@ZacHiggins]

Turning Round I buy it straight from Alumilite on their website. They have all the dyes, powders, and everything you need there. Plus, you can get it in gallons or even larger quantities there. They actually have quite a few different types of resins, which can be confusing. Here are the links to the resin products I use on the Alumilite website: Alumilite White: alumilite.com/ProdDetail.cfm?Category=Casting%20Resins&Name=Alumilite%20White%20(Amazing%20Casting%20Resin) Alumilite Clear: alumilite.com/ProdDetail.cfm?Category=Casting%20Resins&Name=Alumilite%20Clear It's much cheaper to buy it in gallons, but it does have a shelf life. I think it should be good for 6 months to a year as long as you keep it in decent conditions (no extreme heat or cold). If you're in a hurry and an Amazon Prime member, you can get the 32 ounce resin in clear or white in two days. Nice if you're in a hurry, but unless you're in a hurry I would just buy it from Alumilite.

[@Tsunamiguitars]

Zac, I recently saw a three part video where Woodcraft Spokane did about the same thing with the white, not using a pressure pot. Why use a pressure pot on somthing that is basically cured in under 10 minutes? I have a pressure pot, but don't use it for the polyester casting resins in PVC tubing or the white alumilite in molds. Have not see much in the way of bubbles on either.

[@ZacHiggins]

+Tsunamiguitars I use pressure to ensure that there are no air bubbles in the casting. Alumilite White hardens so quick that air can get trapped in the casting with only 2 minutes of open time. Pressure isn't as necessary if the resin is slow setting because there is more time for the air bubbles to free themselves. I cast under pressure regardless of which resin I'm using though. Casting under pressure has no drawbacks, all it will do is help ensure a bubble free casting. For Alumilite White, I'd say it's the difference between not seeing "much" in the way of bubbles and not seeing any bubbles.

[@Tsunamiguitars]

+Zac Higgins Zac, that seems opposite to me. Maybe I don't understand. I've only poured the white twice, in open faced silicone trays about the size of pen blanks I found in a Walmart. The white cured from the inside out, and was cured fully about ten minutes. It was probably hardened in the middle about like you say, 2-4 minutes. By the time you mix, swirl in any color, and get it in a pressure pot, it would seem a moot point. Since pressure pots make the air so small it cannot be seen, (opposite of vacuum, which pulls the air out), as soon as the cure is hard enough to defy 50-60PSI, (maybe three minutes in the middle), only the slower setting Aluminites can benefit from the air, like my Nebula pens, which were the slower curing Alumilite water clear. Still able to have air compressed after 30 minutes. But I will say I have not turned any of those Alumilite white blanks yet, just poured and examined them. You obviously have a lot more pours under your belt than I! I'll defer to your expertise. By the way, the blue yellow windstorm swirl pen was cast poly resin, not Alumilite. I used yellow and blue pearl powder and a bit of pearl white. I learned what you meant by "chippy" on the cast poly resin. Happens when you lathe it. Very interesting. I ended up cutting it big and sanded it into position. And it is harder to get a mirror shine on that poly product. So cheaper coming in, but more time and trouble on the other end. Finally, the Nebula pens were the Banksia pod with the tiny bit of Behlen yellow and blue dye (using Alumilite water clear), much clearer and only used to enhance the beauty of the wood and hide the brass a bit. Thanks for everything! I enjoy your videos!

[@petergoumans6026]

Where do you buy your pressure pots I want to try testing myself

[@ZacHiggins]

I get them at finishsystems.com Check the navigation menu in the left column on their website for "resin casting" pressure pots, they are slightly faster to set up for resin casting. Basically just don't have the extraneous parts on it that we would take off anyway

[@littlebullseye901]

How well does alumilite white turn out without a pressure pot?

[@ZacHiggins]

+Matthew Wilson Pretty good, might have a couple air bubbles here and there, but usually it's pretty clear.

[@brandonzachry9719]

Thanks for posting. Nice shop!

[@ZacHiggins]

Thanks Brandon, and thanks for watching

[@Vahan210]

I'm just starting to do my own blanks. do you use mold relies when you casting?

[@ZacHiggins]

+Vahan Muradkhanyan Just depends on what the mold is made out of. I don't use a release on silicone or HDPE (cutting boards). I do use it on melamine and PVC pipes. Glad to hear you're getting into casting, can't wait to see what you make!

[@Vahan210]

I just ordered alumilite clear. going to try that out. I'm actually looking foreword to it. thanks for answering. i like your videos too. keep them coming.

[@ZacHiggins]

+Vahan Muradkhanyan Thanks Vahan! If you have any questions, give me a holler.

[@JohnSchulte]

Thank you for taking the time to share. What pressure are you using on the pot, and for how long?

[@ZacHiggins]

Hey John, thanks for watching glad it is helpful. That pressure pot is rated at about 80 pounds MAX (which I'm pretty certain means that it will fail at 80), so I usually run about 40-50 pounds. The length of time is just based on however long it takes for the resin to harden. The Alumilite White will be hard in about 10 minutes, and for the Alumilite Clear maybe 20 to 30 minutes. I usually de-mold Alumilite White after 30 minutes, and Alumilite Clear after an hour or so. Again, this is strictly for Alumilite resin, not PR or epoxy. Hope that helps, let me know if you have any other questions and I'll try to help out. Also, let me know if you have any specific things you'd like to see me shoot on video.

[@JohnSchulte]

Zac Higgins Thank you. Looks like your tank is 2.5 gal.? I'm not a pen turner, but I have a shop and work with wood and do some turnings. I really like your idea of casting wood and that's what I will be watching next. I seem to make a lot of lamps and bowls so I've been researching inlays and such and got to you. After watching you, I'm going to play with combining wood with resin, maybe doing some segmented bowls with it, maybe drilling holes in wood and filling with resin and then turn. Not sure yet, but like you I love experimenting.

[@ZacHiggins]

John Schulte Heck yeah, that's awesome! I hope you share some of your creations. After reading the types of projects you listed, I also wanted to suggest a KZbin channel that's right up your alley! I'm not sure if you've come across Brendan Stemp's channel, but definitely check him out. He does some awesome acrylic/wood mixtures including pepper grinders, overlay pours, inlays, and even casting acrylic bowls.

[@bejeweledbybea]

Hi. I have not worked with resin but I'm interested in making handles for crochet hooks. Any advice you can give me?

[@ZacHiggins]

+bejeweledbybea Well, I don't know much about crochet hooks, but I can probably help out if you have any specific questions about casting. What's holding you back from getting started?

[@bejeweledbybea]

I think I'm just going to have to take the plunge. :-) Would you cast a blank then drill and add the hook or add the hook while it's hardening?

[@ZacHiggins]

+bejeweledbybea I'd say go for it. I jumped in head first and I have no regrets. As with anything, you will have to expect a few failures along the way, but casting is pretty simple overall. Plus it's really fun to experiment with! It wouldn't be too difficult to cast the hook in the resin, but if you will be working on the handle after it's cast (turning, shaping, sanding, etc.), it would probably be easier to do without the hook in it. You might need to rig something up that will make sure the hook goes in and stays aligned properly if you decided to embed it while casting. It shouldn't be difficult to come up with a way to hold the hook over the mold in the right position, but it may be easier to just drill it out depending on what tools you would use to drill it. If you will be using a drill press to drill it out, that would probably be the simplest way to ensure that the hook is going in where and how you want it. Using a hand drill without some sort of guide would probably be less accurate than embedding it in the resin during casting (as long as you've rigged something up to hold the hook in the right position). Hope that helps out a bit, and I hope that wasn't totally confusing. Just trying to think of as many pros and cons to each way of doing it. You may have to give both methods a shot and see which works best for you.

[@bejeweledbybea]

Thank you so much for your time and opinions. Much appreciated. :-)

[@ZacHiggins]

+bejeweledbybea I'm glad to help out. Let me know if you have any other questions while you get started. Definitely send some photos of these when you start making them too, I'd love to see them.

[@airdakota]

Where did you get pressure pot?

[@ZacHiggins]

Hey MC, thanks for watching. I got the pressure pot at Harbor Freight. If you decide to get one at HF, make sure you get a 20% off coupon first, should save you about $10 on it. You can also find pressure pots for around the same price on Amazon and Grizzly

[@sreihart]

+Zac Higgins Thank you for the notice about the coupon! We just got a HF in my area and I can now go to their store. I didn't know they offered coupons so I'm going to get the pressure pot with the coupon. Thanks buddy! -Sharryn

[@ZacHiggins]

+sreihart Nice!! You're going to have a field day now that HF is opening. Just make sure to grab your coupons before you walk in there :-)

[@sreihart]

I already printed them out LOL!