Dr. HC Hubert Schuster Jewelry Technology Institute, Vicenza, ITALY

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1 Dr. HC Hubert Schuster Jewelry Technology Institute, Vicenza, ITALY Hubert Schuster is President of the Jewelry Technology Insitute of Vicenza. He has a long experience and deep knowledge in the goldsmith field, and is considered one of the top experts for rubber moulds. He consults for many goldsmith companies throughout the world. The materials available today to jewellery makers for the preparation of rubber moulds enable to do almost everything. However, one must have clear ideas on the mould engineering. This paper will discuss various methods, both traditional and innovative, to produce moulds that enable to obtain a final product with the best quality.

2 New Techniques in Preparing and Cutting Rubber Introduction The Lost Wax Casting process is very ancient, but industrial jewellery production with this method started only in the last century. A simple, quick and accurate reproduction method was needed for mass production purposes. Natural rubber represented an excellent material for this purpose. In the meantime, other materials with many beneficial characteristics were developed, such as silicone rubber and RTV (Room Temperature Vulcanising). To reproduce a piece of jewellery in large quantities a high quality master model is required. It can be made of metal, wax, synthetic resin or other organic material. Depending on the specific requirements of the item to be produced, the appropriate type of rubber is needed to make the mould. Knowing the different properties of every material is important, in order to obtain the best possible result. It is just as essential to have full command of the various rubber cutting techniques, which can be achieved with a good initial training and constant practice. Only people with considerable manual capability, lots of patience and some talent are suitable for this type of job or better yet, this kind of profession. Content The following topics are discussed in this presentation: Equipment, optional helping tools, mould materials, different mould frames, vulcanising and curing systems, premier objectives of mould cutting, separation and cutting systems, optional air release cutting systems, release spray or powder, wax injectors, injection waxes, mould maintenance and storage, wax patterns cleaning and storage, conclusion and thanks. Equipment Vulcanizer There are many different models of vulcanizers available in the market: 1. with round heating plates and central piston 2. with square plates and without central piston 3. with single/dual temperature adjustment June

3 4. with manual screw tightening system, Figure 1a 5. with pneumatic tightening system by manual pump or attachment to a compressor, Figure 1b. 1a) - With manual screw tightening system 1b) - With pneumatic tightening system Figure 1 - Vulcanizers Mould remover This device is mainly used to remove the rubber quickly and easily from round frames, Figure 2. Figure 2 - Mould remover Mould cooler Specially for heavy and solid waxes, it is recommended to cool the mould for better results, Figure 3. It is a helpful equipment also in summer time. Figure 3 - Mould cooler - Mould-opening pliers, reverse pliers - Permanent marker, to mark the cutting line on the master model. - Scalpel handles, with straight and curved blades - Magnifying glasses, for delicate and precise cut. 228 Jewelry Technology Forum

4 - Silicone wheels and micromotor, to remove possible defects, Figure 4. Figure 4 - Different tools "Third hand" It is made of a single or double hook which is securely fixed onto the bench and is utilized to firmly hold the rubber open while being cut. Others prefer the crocodile clamps fixed onto the bench or tied to a chain, Figure 5. Figure 5 - "Third hand" Protection gloves Are needed to protect your hand from a slipping scalpel. Rubber burner Sometimes it is necessary to carry out minor repairs or modifications on the mould. A simple "pyrograph" with various interchangeable tips is the ideal tool for this job, allowing to burn off also the silicone rubber moulds, Figure 6. Figure 6 - Rubber burner June

5 Thermometer It is recommended to carry out periodical checks on the vulcanizer, to make sure that the set temperature corresponds to the real one, Figure 7. It is advised to calibrate every vulcanizer and to measure the temperature of the upper and lower heating plates individually. Figure 7 - Thermometer Hardness tester Each rubber type has different hardness. With this tester you can measure the "Shore A" hardness of the rubber accurately, Figure 8. Figure 8 - Shore A hardness tester CNC or CAM 3D milling machine This piece of equipment is a must in every workshop. In our case it is used to make the moulds in metal, plastic, artificial wood, plexiglass or other hard materials, Figure 9. Figure 9 - Lathe, milling machine 230 Jewelry Technology Forum

6 Optional helps Needles or pins Such needles come in various sizes starting from a Ø 0,7 mm. upwards and can be found in the precision mechanic parts market, Figure 10. Cooling blades For wax models with a perfectly even surface, such plate is applied onto the flat part of the master model and embedded in the rubber, Figure 10. Figure 10 - Needles, pins and cooling blades Filling items In order to obtain pieces featuring inside parts of high precision, such as in the case of clasps or similar items, a metal form is fitted inside the master model, before putting it in the rubber, Figure 11. Figure 11 - Filling items Joining knobs or locator pins These metallic inserts are used with the tear system and allow tight closing of the rubber while the wax is being injected in the rubber mould, Figure 12. June

7 Figure 12 - Joining knobs or locator pins Micro chips They are introduced in the mould and enable memorisation of all parameters inherent to wax injection, Figure 13. Figure 13 - Micro chip Mould materials Natural rubber Available in rolls or rectangular pre-cut blanks, Figure 14a. Advantages - Higher tear resistance - Needs less release cuts - More cost-effective - Enables easy removal from the frame - Easy to burn Disadvantages - Longer frame filling time - Poor hardness range available - Makes cutting somewhat difficult - Wax tends to stick on the mould, release spray or powder is required - Imperfect and rough wax surface - Causes oxidation on silver & brass master models, rhodium plating is suggested. 14a Natural rubber 14b Silicone rubber 14c Liquid RTV rubber 14d Putty rubber Figure 14 - Mould materials 232 Jewelry Technology Forum

8 Silicone rubber Available in square sheets or strips, Figure 14b. Advantages - User friendly - Comes in a hardness range from 32 to 70 shore - Many different shrinkage rates: Easy to cut open - No release spray or talc required - Fast wax patterns removal - Great adherence to detail - No oxidation of silver master models Disadvantages - Difficult to burn, needs very high temperature, above 700 C - Needs more air-release cuts - Lower tear-resistance - Doesn't allow fast removal from the frame - Higher cost Liquid RTV rubber There are two types of liquid RTV rubbers in the market, Figure 14c: 1. bi-component 50/50 with short working and curing time 2. base liquid plus catalyst, ratio 90/10, with somewhat longer working and curing time Advantages - 0% shrinkage - Ideal for very complex or delicate items - Makes easy-to-cut moulds - Wax models can be removed rapidly and with no damage - Excellent reproduction ability - Doesn't need release spray or talcum - Perfect reproduction of delicate models of any materials Disadvantages - Medium tear strength - Needs more air release cuts - Expensive - Difficult to burn, needs very high temperature Putty rubber (Paste) Two types can be found on the market, both have short working and curing times, Figure 14d: 1. bi - compound 50/50 2. Base putty compound plus liquid or solid catalyst 98/2 Advantages - No shrinkage - Quick preparation - Easy to cut - Releases the wax models with no damage Good wax reproduction - Can be used with master models of many different materials, such as metal, resin, hard wax or other hard materials June 2004 Disadvantages - Low tear strength - Breaks easily - Recommended for plain objects only - Burning is very difficult 233

9 Metal or other hard materials This kind of mould is mainly suitable for the injection of plastics. It accepts also injection of hard wax for modelling and very thin patterns can be produced, because injection can be carried out under high pressure. The metal die can be machined starting from a 3D drawing, without the need of a master model. A 3-axes CAM cutter or a CNC system is required for this purpose. Combination of metal/rtv or silicone rubber A very handy method whenever particularly thin wax patterns or plastic pieces must be produced, also with undercuts or intricate forms. Here a master model is necessary, whereas CAD/CAM equipment is not required. Only a thin layer around the master model is of rubber, the remaining die body is of metal. This allows injection of wax or plastic at a high pressure without generating wax fins or item expansion. Mould frames To vulcanise natural or silicone rubber different options of frames are available: 1. Aluminium frames, Figure 15a: - rectangular with various size and thickness - rectangular (or square) single, double and quadruple - round with handle - rectangular, dismountable 2. steel frames, Figure 15b: - round with handle - square or rectangular 3. aluminium frames with steel inserts, Figure 15c - round with handle 4. for RTV liquid rubber, Figure15d - U shape frame 5. tube frames, Figure 15e 6. for putty paste rubber, Figure 15f - Metal single or double frames Instructions for vulcanising It is strongly recommended to purchase only materials that come along with consistent and precise instructions on vulcanising temperature and time. It is also helpful to have an indication of the Shore hardness and of the shrinkage rate. High temperature - for organic rubber: 145 C C, time: 7 min. per layer, shrinkage: 2.5% - for silicone rubber: 170 C C, time: min. 1 hour, shrinkage: % 234 Jewelry Technology Forum

10 15a) - Aluminium frames 15b) - Steel frames 15c) - Aluminium and steel frames 15d) - Frame for RTV liquid rubber 15e) - Tube frame 15f) - Frame for putty rubber Figure 15 - Different types of mould frames Medium temperature - for special silicone rubber: 120 C, time: min. 1 hour and a half, shrinkage: 1.0% - natural rubber "Pink": 140 C, time: 15 minutes per layer, shrinkage: 1.0% Low temperature - for special silicone rubber: 82 C - 95 C, time: min. 2 hours, shrinkage: % Curing instructions In this case too it is recommended to have instructions about mixing and a comprehensive description of the product characteristics and properties. For the liquid rubbers, a vacuum pump with vacuum bell is required. Liquid rubber RTV bi- compound 50/50 Working time: 3-5 minutes, curing time: 1-2 hours June

11 Liquid rubber RTV plus liquid hardening agent 3-10% Working time: minutes, curing time: hours (Curing time can be shortened to 1-2 hours by heating in hot water at C) Bi-compound putty rubber 50/50 Working time: 2-3 minutes, curing time: minutes Putty rubber with liquid catalyst or in paste 2-3% Working time: 2-3 minutes, curing time: 5-10 minutes Primary objectives of mould cutting - Figure16 1. Wax patterns easily removed without distortion: It is obtained with the use of silicone rubber, which doesn't require any release spray or powder, but also the way of cutting the mould is very important. 2. Mould parting line not visible: This can be achieved in the best way by cutting the mould, not with powder separation. 3. Precise wax and complete filling: This depends mainly on different kinds of air release systems in the mould, but also on the wax type. 4. Perfect surface without defects: This depends mainly on the rubber type, silicone rubbers are for sure the best solution, but also the kind of wax as well as the injection system, are playing an important role to achieve the goal. Figure 16 Primary objectives of mould cutting 236 Jewelry Technology Forum

12 Separation systems Powder separation This system doesn't require high manual skill. The preparation of the rubber requires longer time but grants easy-to-open moulds. The outcome is not always flawless and the parting line might be visible. Not suitable for complex objects, Figure 17. Natural and silicone rubbers match the purpose. Talcum powder, vaseline, silicone oil or other materials can be used for the separation. Figure 17 - Powder separation Mould cutting It is for sure the most popular separation system, ideal for any kind of rubber type, and also for any kind of master model, doesn't matter if it is a simple or a very complex one. Mould cutting allows to achieve a very precise parting line along the edges or any desired line, Figure 18. It is advised to study the cut in every detail and to make a line on the master model with a permanent marker before placing it in the rubber mould. This is a precious guide during the cutting process. Figure 18 - Mould cutting with scalpel Powder separation and cutting On several different occasions, such a system will offer the most convenient solutions that will ensure the best results, Figure 19. June

13 Figure 19 - Powder separation and cutting Two phase moulding Not a widely used method, can replace the tear separation or even the separation by cutting, Figure 20. Quite time-consuming and laborious process, ensures outstanding results in return. Not recommended for intricate shapes or that are difficult to remove from the mould. Figure 20 - Two phase moulding Air release cuts Air release channel: For very fine items, an air-release channel enables an easier flow of the injected wax, because no resistance is encountered by the air being entrapped in the mould, Figure 21. Figure 21 - Air release channel 238 Jewelry Technology Forum

14 Air release cuts: To make air-release cuts at the edges and corners of the rubber, in order to create an exit for the air during the injection and to remove the wax without deformation, Figure 22. Figure 22 - Air release cuts Vacuum chamber: Applies to vacuum wax injectors only. Before injecting the wax, a vacuum is created also in the prepared chamber, during the injection, this depression creates a suction effect, Figure 23. Figure 23 - Vacuum chamber Air valve system: Concerns vacuum injectors only. This valve allows only outgoing and not incoming air, Figure 24. Figure 24 - Air valve system Air/wax suction systems: During injection, the air and the wax are being sucked at the same time from the side opposite to the injection point, through channels being purposely made in the rubber, Figure 25. This method gives excellent wax patterns, but a special injector is required. June

15 Figure 25 - Air/wax suction system Release spray or powder Silicone spray: Allows to take complex and delicate wax patterns out of natural rubber moulds. Prevents wax from sticking onto the rubber, Figure 26. Figure 26 - Examples of silicone spray Silicone oil: It is mainly used when it is necessary to take off rubber inserts from the wax pattern, before opening the mould. Vaseline: Can be used instead of talcum powder for moulds with powder separation. Talcum powder: Talcum keeps the vents in the mould open, for the air escape. Any contact with the wax should be avoided because the powder would make the surface wrinkly. Moreover, talcum causes porosity during casting, because it leaves residues in the investment, Figure 27. Flour: Same application as the talcum. It is completely combustible and is eliminated during the burnout without leaving any trace. Therefore it causes no porosity, but still a slightly rough surface, Figure 27. Figure 27 - Talcum powder, flour or substitutes 240 Jewelry Technology Forum

16 Wax injectors With air pressure: In this traditional system the pressure can be provided by an air pump or air compressor and is regulated through a pressure regulator, Figure 28. Figure 28 - Air pressure wax injector Pneumatic pressure: Instead of air pressure on the wax, a pneumatic system is used; the advantage of this system is less air bubbles entrapped in the wax, Figure 29. Figure 29 - Pneumatic pressure wax injector Figure 30 - Vacuum wax injector with hydraulic clamp Figure 31 - Multiple vacuum wax injector With vacuum: The vacuum draws air out of the moulds before wax is injected, Figures 30 and 31. It is ideal for filigree items, reduces also entrapped air bubbles and is more effective with silicone rubber. June

17 With suction: The air is sucked out from the opposite side of the injection, Figure 32. Injection and suction are performed at the same time: this is a very effective system for thin and filigree items. The rubber mould has to be prepared especially for this injector. Figure 32 - Air suction wax injector With parameter setting systems: Different systems allows to record all ideal parameters in the mould with a mechanical (German) or digital (American or French) system, Figure 33. The mould is placed in an autoclamp, where all recorded parameters are transferred to the injector, which is immediately set up for the proper injection, so that constant weight and quality of wax patterns are guaranteed. Figure 33 - Wax injector with a parameter setting system With rotating table: This system has been specially developed for high production rates. It enables to produce a double amount of wax patterns, compared to a traditional system, but only if it is combined with a mechanical or digital parameter setting system, Figure 34. Figure 34 - Rotating table wax injector 242 Jewelry Technology Forum

18 Injection waxes The most suitable wax type should be selected according to the kind of items to be produced. Having a number of injectors, each containing a different wax type, is a practical method for having always on hand the type of wax that best meets the requirements of the items to be produced. Apart from the widely known wax types, there are also some less known but interesting types of wax. Their characteristics make some results possible, that are not obtainable with the conventional types of wax. One of them is a very fluid wax that can be injected at a considerably lower pressure and is ideal for particularly fine items (as for ex. a heart). Another one is commonly used in the electroforming process and is suitable for solid, large and squared pieces. With 0 shrinkage, yields perfect flat surfaces even with large objects (no unwanted depressed areas). Physical properties - Injection temperature: The injection temperature should be close to the solidification point, to reduce wax shrinkage. - Injection pressure: The lower the required pressure, the more accurate and consistent will be the reproduction of the model. - Flow: Better flow properties allow lower injection pressure and give better reproduction of details. - Flexibility: This property is required for wax setting but also to remove complex waxes from the mould without distortion, deformation or breakage. - Shrinkage: Low shrinkage is required, especially for thick shapes with flat surfaces. - Memory: It is important that deformed waxes return to their original shape after being removed from the mould. - Shelf life: This property is required for the storage of waxes, flexible waxes are more suitable for storing. Mould maintenance and storage - Every now and then clean the rubber moulds with soapy water using a tooth brush. - Store the moulds in a closet, to keep them away from dust. - Mark the moulds with the item number and classify them orderly. Wax treatment and storage - Each single wax piece should be checked under a magnifying lens and repaired if necessary. - Only certain types of wax have a long shelf life. June

19 - Keep the waxes in a closed environment at room temperature and away from sunlight and dust. Conclusions I believe that cutting of rubber moulds is a separate profession, even if it is of course also part of the complex process of investment casting. A thorough knowledge of the materials, with their peculiar characteristics and instructions for use, is of vital importance. Selection of the appropriate rubber type in view of the shape and type of model is determining for the quality of the wax patterns. An accurate study of the cutting method to use, before putting the model in the rubber, is another basic rule, and is necessary to reach an optimal result. The cutting technique has to be well-taught from the very start, but requires constant practice thereafter. Acknowledgements - Nicem S.p.A., Italy - Pasini Gioielli S.r.l., Italy - Raselli S.p.A., Italy - Maiorana, Italy - MDM S.p.A, Italy - Gaudenzi S.r.l., Italy - Maxmatic, France - Cv. Citra S.S., Indonesia - Novo Tecnica, Thailand - Diatrends Ltd., India - Sunjewels Pvt. Ltd., India - Emerald Jewellery Creator Ltd., India - Mr. Wilson Quadros, India - Favori, Turkey - Arin S.A., Peru - Rio Grande, USA 244 Jewelry Technology Forum

20 June

Dr Hubert Schuster - Jewellery TECHNOLOGY INSTITUTE HUBERTSCHUSTER Creazzo - Vicenza, Italy

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