Casting w/ Alumilite Fillers

Posted by [email protected] BigCommerce on Sep 22nd 2021

Casting w/ Alumilite Fillers

How to cast using dry fillers.

Dry Fillers can be mixed into Alumilite Casting Resin to add different characteristics and to extend the volume of the resin. Any dry filler can be added into the Alumilite Resin. We offer 4 different fillers (microballoons, tungsten powder, porcelain powder, and phosphorescent [Glow] powder). You can add up to 100% by volume. Microballoons add space and buoyancy to your cast part. If you are looking to make your part lighter, have it float in water, or to use significantly less resin try using mircoballoons. Tungsten Powder is used to add weight. Porcelain Powder is used with Alumilite White Casting Resin to achieve cold cast porcelain. It gives the user the look, feel, and texture of a porcelain casting. Use the porcelain in conjunction with the flesh tone dyes to duplicate one of a kind dolls and sculptures. Lastly, phosphorescent powder is added to Alumilite White or any of our clear casting resins to produce a uniform luminescent glow.

Products Used


Step 1 Gather materials

The first step is to gather the materials that are needed. Alumilite Casting Resin, a stir stick, cups, filler (we are using microballoons), and your mold.

Step 2 Measure resin and filler

Next measure equal amounts of both sides of Alumilite's Casting Resin based on mixing directions for your particular resin. Then measure equal amounts of the microballoons for each side of the resin. Add the filler to both sides of the resin before mixing the two sides of resin together, this will provide you with a better mix and more consistent results. Here, we are going to add 100% of microballoons (by volume) to our resin. In other-words, for every ounce of resin used, one ounce of microballoons are added.

Step 3 Measure and add filler to each side of resin

Mix equal amounts of each side of the resin with the same amount of microballoons (the 'B' side is being shown in the picture). Repeat this process for the 'A' side.

Step 4 Stir in filler until uniform color is reached

Stir in the microballoons until uniform color is reached. Since you are mixing a substance into the Alumilite, keep in mind that you are also thickening the Alumilite. When you eventually mix the two sides together and pour the microballoon filled resin into your mold, the consistency or viscosity will be a little thicker.

Step 5 Pour both side of resin together

Pour both sides of the Alumilite Casting Resin with microballoons into a cup.

Step 6 Stir thoroughly

Stir until uniform color is reached (about 25 seconds).

Step 7 Pour resin into mold

Slowly pour resin into your mold. Remember, you can tip the mold a little while you pour to help fill in any undercuts and reduce the chance of air bubbles.

Finished Project

These two casts from the same mold turned out so different!! I am really looking forward to seeing how using just the wings works out too. What a versatile mold!