MOULDING

(Dye Making): 3 steps for moulding (a) Dye Packing (b) Valconizing
(c) Dye Cutting
A: DYE PACKING
Requirements: Master Model, Frame, Frame Plate, Funnel, Handle, 12 No.
Blade, Scissor, Scale & Rubber.
Procedure: Select frame according to the master model and cut rubber
according to frame and cut rubber according to the frame cut required
number of rubber strips according to height of frame.
Normally dye is maximum of 6 layers. When we are ready with 6 rubber
strips of frame size. Along the width of two strips, cut a equilateral triangle
(V Shape) with 1 cm side from mid point.

Peel of blue wrapper from one of the 4 other strips and yellow wrapper for
another strips and stick both of them. Stick the other two strips in the
same way. Peel if yellow wrapper from one of two strips with V cut and
peel off blue wrapper from double strips and stick them. Stick the other
double strip and strip with V cut in same way. Now peel off blue wrapper
from 1 set of 3 strips and place master model with funnel. Fill some extra
rubber in both space on both side of master model. Peel off blue wrapper
from other set and stick both sets.
NOTE: WASH YOUR HANDS PROPERLY BEFORE STARTING DYE
PACKING.

B Valcanizing:
Valconizers are two types (I) Manual (II) Automatic
We do our maximum work on manual because of it is less risky in terms of
damage to dye. In manual Valcanizer need 10 minutes pre heat before
doing work.

VALCANIZING TEMPERATURE
TEMPERATURE (0C)

TIME (MINUTE)

1 Dye

145

55

2 Dye

150

60

3-4 dyes

155

65

1 Dye

150

60

2 Dye

155

65

3-4 Dye

160

70

1 Dye

155

65

2 Dye

160

70

3-4 Dye

165

75

Normal Dye (6 layers)

Medium Dye (7-8 Layers)

Heavy Dye(9-10 Layers)

Temperature Problem: If temperature of Valcanizer is lower than

required then low temperature problem arises.
Test: After taking out dye frame from Valcanizer, press dye with finger, if
a impression is left then there is low temperature problem.
Solution: Keep dye in Valcanizer with plates at right temperature for 15
to 20 minutes.

Effects: In this case life of dye decreases by 20% to 30%.

If temperature of Valcanizer is higher then required temperature then high
temperature problem arises.
Test: Take out dye from Valcanizer press dye with finger. If a impression is
left with some sticky feeling means temperature is higher by 10 0C 200C
then required.
Moment we release pressure of Valcanizer, if dye expands it means
temperature of Valcanizer is higher by 400C or more.
Effect: In both cases dye is damaged.
Hold dye frame and dip it in water to cool it also dye will shrink and it will
be easy for us to take out master model. Clean the master model properly.
Timing Problem: If time of Valcanizer is less then required than less time
problem arises.
Test: After taking out dye frame from Valcanizer, press dye with finger, if
a impression is left then there is less time problem.
Solution: Keep dye in Valcanizer with plates at right temperature for 15
to 20 minutes.
Effects: In this case life of dye decreases by 20% to 30%.
If time of Valcanizer is more than required then High Time Problem arises.
Test: Take out dye from Valcanizer press dye with finger, rubber of dye
sticks with finger and it comes with finger.
Effect: Dye is damaged.
Hold dye frame and dip it in water to cool it also dye will shrink and it will
be easy for us to take out master model. Clean the master model properly.
Pressure Problem: If pressure is more, it does not effect dye.
Low Pressure Problem: If pressure is slightly low then in top and bottom
layer there will be bubbles and inside dye is normal.
Effect: Life of dye is reduced by 30%. If pressure is very low then bubbles

will be there in whole dye.

Effect: Dye is damaged.
Electric Problem: After keeping dye in Valcanizer, if there is electricity
break down then Electric Problem arises.
Time Period of Electricity Break
Down

Additional Time

5 Minute

0 Minute

10 Minute

5 Minute

15 Minute or above

10 Minutes

C Dye Cutting:
First take out frame from Valcanizer and separate the frame plate. Check
the dye whether it is correctly Valcanize or not. If it is correctly Valcanized
then take out dye from frame and cut off extra rubber from dye. Now we
have neat and clean dye. Remove funnel from dye, then with 12 number
blade, mark 2mm deep cut and the middle of height on all the sides. Now
keep dye on table with rough side up. With 12 No. blade make a cut 90%
deep from the middle with 800 angle of holder at all corners.

After cutting 4 sides turn dye with smooth side up. Now turn
wall with thumb and make a 10% to 15% deep horizontal cut. Stretch
the wall a little more and make a vertical cut in triangle shape, cut all
three remaining corners in the same way.
For further cutting we will use hook and clamp. First fix hook
and clamp on table. Hold the wall of dye with thumb of left hand and fix
lock of dye in hook. Cut zig-zag shape (interlock) near the sprue with
12 No. blade and make a straight cut, do same on all sides corner.
For further cutting use a 11 no. blade stretch the wall start
cutting along sprue from smooth side. Follow sprue and make straight
cuts. Keep on changing the side when we reach master piece make
cuts along its corners. Keep on cutting dye following the corners of
master piece and separate dye into two parts.