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How to Make a Mold From Composite Carbon Fiber

Carbon fiber composites combine resin and carbon-fiber woven mat strips to form a hard material with a high tensile strength and low weight. It is also highly flexible. Carbon fiber composites are used in motorsports and military and aerospace applications. You can create a mold by applying carbon fiber and resin to the original. This durable mold can then be used to cast new pieces from silicone, RTV, vinyl, plaster, fiberglass and many other materials.

Things You'll Need

Original item
Mold release spray
Epoxy resin
Catalyst
Stir stick
Carbon fiber mat
Paint brush

Instructions

- 1
  Hold down the nozzle on the mold release spray and apply a thin coat to the front of the original. Immediately apply a thicker second coat. Cover with at least two more coats.
- 2
  Mix the epoxy resin with the included catalyst according to package instructions. Some resins come pre-mixed, so read all directions carefully to ensure you are mixing it correctly. Stir well with a stir stick.
- 3
  Lay strips of the carbon fiber fabric on the front of the original. Cover the entire surface with the strips of woven fiber, overlapping each strip slightly.
- 4
  Dab a thick coat of resin into the carbon fiber using an old paint brush. Continue until coated fully. Immediately add two to three more layers of carbon fiber and resin.
- 5
  Allow to cure for up to 24 hours before removing the mold from the original.

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