Is Design-Cast a resin based material?

No. It is a synthetic, mineral-based product that hardens when mixed with water. Fully hardened material is as hard as agate. Design-Cast feels cool to the touch like stone, not warm like a plastic.

Is Design-Cast a new product?
How long has it been around?

Design-Cast 62 and 66 have been used in both sculpture and architecture since the early 1980's.

Is Design-Cast toxic, hazardous, or smelly to use like some resin products?

No. You only have to take the same common-sense precautions as you would with plaster or water clay, such as not to breathe in the dust. The fully cured and hardened piece is odorless.

What is the difference between Design-Cast 62 and 66?

DC-62 is intended primarily for casting in a mold; it is more fluid, and has a shorter working time than DC-66. DC-66 is intended for modeling over an armature; it has a pasty to putty-like consistency, and a longer working time than DC-62. The end result qualities of DC-62 and DC-66 are the same.

How do I estimate how much material I will need?

For each one square foot at the typical 3/8" - 1/2" thickness for a "thin-shell" piece, you will need 3 to 4 pounds of Part A (dry mix), and the corresponding amount (1/10) of Part B (polymer).

To get the best result what are the most important things to remember?

Use a scale to measure the proportions of dry mix, polymer, and water—do not try to guess or "eye-ball" the quantities. Mix dry with wet materials thorougly with a mechanical mixer—not by hand, and be consistent from batch to batch. Keep the piece wet for at least 24 hours after mixing and casting or modeling, so as to achieve full hardness and strength.

What color is Design-Cast?

White. Or to be more precise, a very slight off-white with a neutral gray undertone.

How do I color Design-Cast?

You can use almost any pure dry pigment that is stable to sunlight and weather. We recommend using pure natural or synthetic mineral-based pigments where possible for the color you want—such as iron oxides for blacks, browns, yellows, or reds; chrome greens; cadmium reds or oranges; copper or cobalt blues. To color Design-Cast throughout, mix in the pure dry pigment with the Part A (dry mix) before adding to the Part B (polymer) and water. For a more brilliant white than the natural color of Design-Cast, use a few percent (%) of pure titanium dioxide white pigment.

How much pigment will I need?

Typically, add up to 1% (by weight of dry mix) for pastels, or up to 5% for deep colors.

Are there any materials I should NOT use in Design-Cast?

Aluminum. Do not mix in aluminum powder, or use aluminum metal for reinforcement. Aluminum is not compatible with unhardened Design-Cast.

Can I apply paints, patinas, or sealers?

Yes. First make sure that the surface is clean and free from any oily or waxy material, or mold release. If you are using a non-water-based coating, also make sure the surface is dry. Most high quality coatings adhere well and are compatible with Design-Cast surfaces. Of course for exterior exposure, the coating must be an exterior grade material.

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Last update: Tuesday, August 27, 2002