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Guide: laminating with acrylic resin (making a support shell)
Laminating with acrylic resin (making a support shell)
With this guide you learn to laminate with acrylic resin and triaxial fibreglass cloth. The technique is ideal for making a strong, lightweight support shell for a silicone mould, or for reinforcing an acrylic resin cast. You work wet on wet for the best adhesion.
📄 Download this guide as PDFWhat are you going to make?
You build up a strong acrylic resin laminate layer by layer with triaxial fibreglass cloth and chopped fibreglass as reinforcement. The result is a sturdy support shell or a reinforced acrylic resin cast. Because acrylic resin adheres best when you work wet on wet, you apply each new layer before the previous one has cured.
💡 Working wet on wet means the previous layer is not yet cured (wet) before you apply the next layer. So work promptly, one after another.
Required materials
🛒 From the webshop
🧰 Supply yourself
- Mixing cup(s)
- Mixing spatula
- Scale
- Scissors
- Acrylic resin colorant (optional)
- Mould or model to coat
Processing data
| Property | Value |
|---|---|
| Mixing ratio acrylic resin | A : B = 1 : 2 (1 part liquid, 2 parts powder) |
| Example mix | 50 grams liquid + 100 grams powder = 150 grams |
| Thix A thickener | 2% by weight |
| Chopped fibreglass in filler resin | around 5% by weight |
| First resin layer thickness | at least 1 mm |
| Method | wet on wet |
Preparation
Lay out everything before you start so you can work wet on wet, one after another. Clean the mould or model well and place it firmly on a flat surface.
Pre-cut strips of triaxial fibreglass cloth to the size of the mould so you can press them straight into the fresh resin.
⚠️ Acrylic resin has a limited working time. Mix an amount per layer that you can process within that time, and clean the brush and mixing cup with water in between before the resin cures.
Lay out the materials
Lay out all materials: acrylic resin set, triaxial fibreglass cloth, chopped fibreglass, Thix A, mixing cup, spatula, scale, wide brush and scissors. The mould is cleaned and ready to be coated.
Mix the acrylic resin
Pour an amount of acrylic resin liquid (A component) into the mixing cup and add twice as much acrylic resin powder (B component). In this example 50 grams liquid and 100 grams powder.
Mix the 150 grams of acrylic resin well into an even paste.
Add thickener and optional colorant
Add 2% Thix A to the mixture (so 3 grams for 150 grams). Mix the Thix A in well so the resin becomes evenly thick.
Add acrylic resin colorant if desired. This is the color that will be visible later.
Apply the first resin layer
Take a wide brush and coat the mould completely with the paste. Go carefully along the edges and corners and make sure the whole surface is covered with at least 1 mm of resin.
⚠️ On a mould with fine or many small details, it is important to dab or stipple well with the brush so the air is pushed out of the mould.
Lay in the first layer of cloth
Cut a strip of triaxial fibreglass cloth to the size of the mould and press it gently into the resin. Make sure you do not push the cloth all the way through the resin.
Cover the cloth with resin
Apply the remaining resin into the mould until the cloth is fully covered.
Clean tools in between
Clean the brush and mixing cup under the tap in between so they are ready for the next layer. As long as the resin has not cured, the material is easy to clean with water.
Mix filler resin with chopped fibreglass
Mix another amount of resin including thickener; colorant is no longer needed. Add around 5% chopped fibreglass by weight to the mixture and mix until a nice smooth mass forms.
Apply the filler resin
Apply the fibreglass-filled resin onto the still-fresh previous layer and spread it well with the brush.
⚠️ Make sure the resin and fibre are pressed well into the corners.
Second strip of cloth
Cut another strip of triaxial fibreglass cloth to the size of the mould and press it into the freshly applied acrylic resin layer.
Apply the final resin layer
Mix another batch of acrylic resin and thickener. Apply it with the brush onto the previous, still-fresh acrylic layer and smooth it.
Result
Let the laminate cure fully. You now have a strong, lightweight support shell or reinforced acrylic resin cast.
Additional information
- Always work wet on wet: apply each new layer before the previous one has cured, for the best adhesion.
- Acrylic resin adheres very well to itself, even when an earlier layer has fully cured.
- With a lot of detail in the mould, dab or stipple well with the brush to drive out air.
- Clean tools with water as long as the resin has not cured.
- This technique is suitable both as a support shell for silicone moulds and for reinforcing an acrylic resin cast.
Storage
Store the acrylic resin liquid and powder and the Thix A well sealed, dry and at room temperature so the processing properties are preserved.
Frequently asked questions
What is the mixing ratio of acrylic resin?
Two parts powder to one part liquid by weight, for example 100 grams powder to 50 grams liquid. Then add 2% Thix A as thickener.
Why both triaxial cloth and chopped fibreglass?
The triaxial fibreglass cloth gives strength in multiple directions, the chopped fibreglass fills intermediate layers and corners and makes the laminate compact and strong.
Why work wet on wet?
By applying a new layer before the previous one has cured, the layers bond optimally into one whole and no weak separation forms between the layers.
Can I use this as a support shell for a silicone mould?
Yes, that is one of the main applications. The support shell holds a flexible silicone mould in shape during casting.