DIY Network

Creating Seat Mold Amy Devers creates the seat mold for the stackable chairs. From "Freeform Furniture" episode DFFF-209

Freeform Furniture's host continues the stackable chair trays by putting a wax mole release in the mold she has made. She screws down the mold to the melamine laminate on the MDF. Then she works around the edges to fill in any gaps. She moves the mold to a flat drying surface while the mixture cures and trims it up after five hours of drying time.

Finally, she adheres the seat itself and allows that to cure as well.

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	Room: Before
	Room: After
	Freeform Furniture's Stacked Tray Seats
	The stackable chairs offer extra seating when company visits.
	Host Amy Devers creates silicone seat molds for the stackable tray seats.

Materials:

laminate
1/8" bending ply
urea formaldehyde glue
bending form
vacuum bag
adhesive
vinyl gloves
strapping tape
plastic tube
C-channel
respirator
2 part epoxy glue
flush trimming bit
veneers
foam roller
contact adhesive
plywood
wipe-on polyurethane
MDF
mold release
wax mold release
cotton rag
melamine laminate
closed cell foam
silicone mixture
felt upholstery
foam
white wax pencil
heavy-duty fabric starch
spray adhesive.
blue masking tape
brown craft paper
ruler

Tools:

brayer
laminate trimmer
J-roller
utility knife
sanding block
power drill
steam iron

	Figure A
	Figure B

Create Seat Mold

1. Start by putting a mold release on the inside of the mold so the silicone will slip out nice and easy.

2. Dab some wax on a cotton rag and spread an even coat on the inside of the mold.

3. Use a power drill and screw the mold down to the melamine laminate on the MDF.

4. Put some wax release on the side, stick it down to the bottom of the mold and then mix up the silicone mixture and pour it out on top.

5. After you mix the two parts, place the foam core inside the mold. Then, slowly pour the silicone into the mold (figure A).

6. Work the gel around the edges and fill in any gaps. Give the bottom of the mold a few gentle taps to help the silicone level out and settle.

7. Move the mold to a flat drying surface. This is important to make sure that the gel doesn't shift while it is drying—since liquids always settle to their lowest point of gravity.

8. After a five hour cure time, getting the silicone cushion out is easy. Simply remove the screws holding the mold together with a power drill, then peel out the silicon.

9. Trim off the excess silicone with a utility knife (figure B).

10. Adhere it to the seat itself and the easiest way to do that is to use some of the same silicone compound as an adhesive. Spread some on the back, line it up, drop it on the seat, and wait another five hours to cure.

RESOURCES :

Festool
Website: www.festoolusa.com

Stanley Tools Product Group
Website: www.stanleytools.com

Lie-Nielsen Toolworks, Inc.
Website: www.lie-nielsen.com

Power Tools
Porter Cable Power Tools
Website: www.deltaportercable.com

Gladiator GarageWorks
Website: gladiatorgarageworks.com

Hand Tools
Garrett Wade Co., Inc.
Website: www.garrettwade.com

The Peck Tool Company
Website: www.pecktool.com

Biesemeyer
Website: www.biesemeyer.com

Saw Blades
Forrest Manufacturing Company
Website: www.vacupress.com

Jogensen Adjustable Clamp Company
Website: www.adjustableclamp.com

Adhesives, Abrasives and Safety Equipment
The 3M Company
Website: www.3m.com

Klein Tools
Website: www.kleintools.com

Power Tool Accessories
Woodcraft
Website: www.woodcraft.com

Ulmia GmbH
Website: www.ulmia.de

Shop Equipment
Eagle Manufacturing Company
Website: www.eagle-mfg.com

Delta Power Tools
Website: www.deltaportercable.com

WMH Tool Group
Website: www.whmtoolgroup.com

MacBeath Hardwood
Website: www.macbeath.com

Vacuum Pressing Systems, Inc.
Website: www.vacupress.com