REPLICAST Light
Lightweight Fast-Setting Tooling System
DESCRIPTION
REPLICAST Light is a lightweight fast-setting urethane casting system with good handling and cured properties. It was developed to provide a fast, economical casting system for a variety of applications. It has good compressive strength, so it works well as a lightweight, strong back-up material. It is readily machinable, so changes can be easily made. Lightweight holding and nesting fixtures are another logical use for this versatile material.
HANDLING & CURING
Two-component systems with lightweight fillers added will separate
in storage after a very short time, with the lightweight fillers
actually floating to the top of the storage container. Remixing these
components is tedious and time consuming, and often results in an
inconsistent mixture.
To avoid these problems, REPLICAST Light is provided as a
three-component system, where the lightweight filler is added at the
time of use. For the best results and highest physical properties, mix
the three components by weight. For less critical applications, the
components can be measured by volume- but still try to be as accurate as
possible. In either case, the Part C lightweight filler is added to the
Part B and then “let down” with the Part A.
In three separate containers, measure out the required amount of all
three components needed for the casting to be made. Make sure the Part B
is in a container that will hold all of the components to be used.
Start the mixing process by adding half of the Part C lightweight filler
to the Part B container and mix until smooth, then add the remaining
Part C and continue mixing. At this point, you will have a creamy, yet
thick, somewhat pasty consistency material. Then slowly add the Part A
component and mix it into the Part B and Part C combination. Very
quickly, you will achieve a smooth, liquid viscosity material that will
be very easy to pour. When the mixture is uniform, cast the material and
allow to cure.
REPLICAST Light will gel quickly, and castings can be demolded
rapidly. The demold time will depend upon casting size and thickness,
and shop temperatures. At a 77°F ambient shop temperature, castings of
3″ or more thickness can be demolded in around 30 minutes. Thinner
castings may take longer, up to an hour. At this point, the casting can
be used in non-critical applications. However, if maximum physical
properties are required, the material should be allowed to cure longer.
TYPICAL MECHANICAL PROPERTIES
| REPLICAST Light A/B/C | ASTM Method | |
| Mix Ratio, by Weight | 88 Part A : 100 Part B : 100 Part C | PTM&W |
| Color | Light Gray to Grayish Brown | Visual |
| Mixed Viscosity, @ 77°F | 3750 cps | D2393 |
| Working Time, 4 fl. oz. Mass @ 77°F | 6 – 8 minutes | D2471 |
| Cured Hardness, Shore D | 73 Shore D | D2240 |
| Shrinkage, in./in., Mold # 1, Vol: .053 Gal | .0004 | D2566 |
| Specific Gravity, grams, cc | .85 | D1475 |
| Density, lb./cu. inch | .0307 | D792 |
| Specific Volume, cu. in./lb. | 32.6 | D792 |
| Tensile Strength, psi | 2540 psi | D638 |
| Elongation @ Break, % | 3.6 % | D638 |
| Tensile Modulus, psi | 493,887 psi | D638 |
| Flexural Strength, psi | 5430 psi | D790 |
| Flexural Modulus, psi | 474,360 | D790 |
| Compressive Strength, psi | 5608 psi | D695 |
| Compressive Modulus, psi | 252,505 psi | D695 |
| Izod Impact Strength, Method A, Notched | .21 | D256 |
| Glass Transition Temp., Tg, DMA E’, Onset, Peak | 138°F, 196°F | D4065 |
PACKAGING INFORMATION
| REPLICAST Light | Gallon Kit | Pail Kit |
| Part A | 8 lb. | 40 lb. |
| Part B | 9 lb. | 45 lb. |
| Part C | 2 Gallons @ 4.5 lb. ea. | 2 Pails @ 22.5 lb. ea. |
| Kit | 26 lb. | 130 lb. |