Skip to main content

Castable Mounting Consumables

Our castable mounting consumables deliver reliable, room-temperature curing for heat-sensitive and fragile materials. Choose from high-performance epoxy, acrylic, and polyester resins designed for superior adhesion, low shrinkage, and high sample clarity. Engineered for vacuum impregnation capability, our products ensure accurate results for microstructural analysis.

Shop Online
Castable Mounting Consumables

Key Considerations

Choose the Right Resin

Select epoxy for durability, acrylic for fast curing, or polyester for clarity based on your material requirements.

Room Temperature Curing

Ideal for heat-sensitive materials that cannot withstand compression mounting temperatures.

Vacuum Impregnation

Use vacuum capability for porous materials to ensure complete void filling and reliable mounting.

Introduction

Castable mounting uses room-temperature resins to encapsulate specimens, ideal for heat-sensitive or fragile materials. This method supports multiple samples and cures through resin-hardener polymerization to form a durable mount.

Mounting Methods Comparison

Castable mounting can be enhanced with vacuum, pressure, or UV curing systems. Each method offers unique advantages depending on your sample type, throughput requirements, and quality needs.

Vacuum Mounting

TeraVAC Vacuum Mounting System

Advantages

  • Removes air bubbles for clear mounts
  • Excellent for porous materials
  • Fills voids and cracks completely
  • Prevents resin shrinkage issues
  • Ideal for delicate specimens

Considerations

  • Requires vacuum pump (sold separately)
  • Longer cycle time than UV
  • Manual operation on standard models
View Vacuum Systems

Pressure Mounting

TeraCOMP Pressure Mounting System

Advantages

  • Eliminates bubbles effectively
  • Faster than vacuum alone
  • Compact and easy to use
  • Works well with most resins
  • No external pump required

Considerations

  • Less effective for very porous materials
  • Requires compatible pressure chamber
  • May not fill deep internal voids
View Pressure Systems

UV Mounting

TeraUV UV Curing System

Advantages

  • Fastest curing (5-15 minutes)
  • High throughput capability
  • No heat generation
  • Consistent, repeatable results
  • Energy efficient

Considerations

  • Requires UV-curable resins
  • Limited penetration depth
  • Not suitable for opaque specimens
  • May need vacuum/pressure for bubbles
View UV Systems

Resin Properties Comparison

Property Epoxy Acrylic Polyester
Type Epoxy resin and hardener Acrylic resin and powder Polyester resin and hardener
Peak Temperature 100-375°F 150°F 100°F
Shore D Hardness 82 80 76
Cure Time 1-5 hours 8-15 minutes 30-45 minutes
Clarity Clear to slight yellow Semi-transparent Very clear

Products

Acrylic Resins

Description Quantity Catalog Number
ACRYLIC PLUS resin kit 1 lb resin with 12 oz hardener ACYP-5000-K1
ACRYLIC PLUS resin kit 5 lb resin with 1/2 gallon hardener ACYP-5000-K5
ACRYLIC PLUS resin powder 1 lb (454 gms) ACYP-5000-P1
ACRYLIC PLUS resin powder 5 lbs (2.2 kg) ACYP-5000-P5
ACRYLIC PLUS resin powder 25 lbs ACYP-5000-P25
ACRYLIC PLUS resin powder 100 lbs ACYP-5000-P100
ACRYLIC PLUS hardener (clear liquid) 12 oz (0.36 l) ACYH-5000-H12
ACRYLIC PLUS hardener (clear liquid) 32 oz ACYH-5000-H32
ACRYLIC PLUS hardener (clear liquid) 1/2 gallon ACYH-5000-H64
ACRYLIC PLUS hardener (clear liquid) 1 gallon ACYH-5000-H128
ACRYLIC PLUS hardener (clear liquid) 5 gallons ACYH-5000-H640

SUPERMOUNT Acrylic Kits (with filler)

Description Quantity Catalog Number
Glass Filled Acrylic kit 1 lb resin with 12 oz hardener GRAK-5000-K1
Glass Filled Acrylic kit 5 lb resin with 1/2 gallon hardener GRAK-5000-K5
Glass Filled Acrylic powder (black) 1 lb (454 gms) GRAR-5000-P1
Glass Filled Acrylic powder (black) 5 lbs (2.2 kg) GRAR-5000-P5
Liquid hardener 12 oz (0.36 l) GRAH-5000-H12
Liquid hardener 32 oz GRAH-5000-H32
Liquid hardener 1/2 gallon GRAH-5000-H64
Liquid hardener 1 gallon GRAH-5000-H128
Shop Acrylic Resins

Epoxy Resins

Description Quantity Catalog Number
Epoxy Resin 32 oz (0.95 l) EP-3000-32
Epoxy Resin 1 gallon (3.8 l) EP-3000-128
Epoxy Hardener 8 oz (0.24 l) EH-3000-08
Epoxy Hardener 32 oz (0.95 l) EH-3000-32
1-gallon pump dispenser each ED-3000-01

ULTRATHIN 2 Low Viscosity EPOXY Resin

Description Quantity Catalog Number
ULTRATHIN 2 Low Viscosity Casting Epoxy Resin 32 oz (0.95 l) ULTRA-3000-32
ULTRATHIN 2 Low Viscosity Casting Epoxy Resin 1 gallon (3.8 l) ULTRA-3000-128
ULTRATHIN 2 Viscosity Hardener 8 oz (0.24 l) ULTRA-3000H-08
ULTRATHIN 2 Viscosity Hardener 32 oz (0.95 l) ULTRA-3000H-32

EPOXY-ELITE (Environmentally friendly) EPOXY Resin

Description Quantity Catalog Number
EPOXY-ELITE Casting Epoxy Resin 32 oz (0.95 l) ELITE-3000-32
EPOXY-ELITE Casting Epoxy Resin 1 gallon (3.8 l) ELITE-3000-128
EPOXY-ELITE Viscosity Hardener 8 oz (0.24 l) ELITE-3000H-08
EPOXY-ELITE Viscosity Hardener 32 oz (0.95 l) ELITE-3000H-32
Shop Epoxy Resins

Polyester Resins

Description Quantity Catalog Number
Polyester Resin 1 gallon (3.8 l) POLYCAST-128
Polyester Hardener 2 oz POLYHARD-02
Polyester dye kit 3 colors/pkg DYE-1000
Shop Polyester Resins

Mounting Molds and Accessories

Description Quantity Catalog Number
Reusable two piece plastic molds (1.25") 12/pkg METPREP-0125
Reusable two piece plastic molds (1.50") 12/pkg METPREP-0150
Disposable plastic mounting molds (1") 50/pkg MOUNT-0100
Disposable plastic mounting molds (1.25") 50/pkg MOUNT-0125
Disposable plastic mounting molds (1.50") 50/pkg MOUNT-0150
Reusable Silicon rubber (1-inch diameter) 3/pkg RMOUNT-0100
Reusable Silicon rubber (1.25-inch diameter) 3/pkg RMOUNT-0125
Reusable Silicon rubber (1.5-inch diameter) 3/pkg RMOUNT-0150
Reusable Silicon rubber (2-inch diameter) 3/pkg RMOUNT-0200
Reusable Silicon rubber (2.75 x 1.55 x 7/8-inch rectangular) each RMOUNT-315R
Reusable Silicon rubber (3 x 2 x 7/8-inch rectangular) each RMOUNT-302R

Miscellaneous Mounting Accessories

Description Quantity Catalog Number
Mold release 8 oz (0.24l) MR-1000-08
Mold release 16 oz (0.47l) MR-1000-16
Stirring sticks (6" tongue depressors) 100/pkg SS-1000-100
Mixing cups (3 oz graduated cups) 100/pkg MCUPS-1000-50
Plastic mixing cups (9 oz) 50/pkg PCUPS-050
Plastic specimen mounting clips 100/pkg KLIP-0100
Metal specimen mounting clips 100/pkg MKLIP-0100
1.25" specimen storage containers 25/pkg STORE-0125
Shop Molds and Accessories

Recommended Procedures

  • Clean and thoroughly dry specimens to remove cutting and handling residues
  • Remove debris from molding cups
  • Apply thin coat of mold release compound to molding cup
  • Center specimen in molding cup
  • Accurately measure resin and hardener
  • Mix thoroughly (gentle mixing to avoid producing excessive air bubbles)
  • Pour resin over specimen and cure at room pressure or apply pressure in an autoclave chamber

Tips for Best Results

  • Preheat resin, hardener and specimen to 30°C (85°F) to expedite curing cycle
  • For porous specimens, use vacuum impregnation to fill voids
  • Do not pull vacuum for more than 60 seconds to prevent resin degassing
  • For acrylics, submerge in water bath during curing to reduce exotherm and odor

Troubleshooting Guide

Symptom Cause Solution
Lack of or partial curing Improper or insufficient mixing Remount with proper mixing; check catalyst expiration date
Soft or gummy resins Insufficient curing - low exotherm Heat mount at 90-100°F for 1-2 hours and let cool
Bubbling or cracking Too hot curing exotherm Mount at room temperature; decrease hardener volume
Long curing time Improper mixture or old hardener Replace old hardener; mount at 70-80°F
Bubbles in resin Improper mixing or degassing Mix slowly; use vacuum/pressure; clean specimen

Related Equipment

TeraVac Pro Vacuum Mounting System

TeraVac Pro

Professional vacuum mounting system for void-free epoxy mounting. Features precise vacuum control, digital timer, and easy-to-use interface for consistent, high-quality mounts.

Learn More
TeraComp Pressure Mounting System

TeraComp

Pressure-assisted castable mounting system that ensures complete resin penetration and eliminates voids. Ideal for porous materials requiring superior edge retention.

Learn More
TeraUV UV Curing System

TeraUV

Fast UV-curing mounting system with 405nm LED technology. Cures mounts in minutes with precise temperature control, perfect for rapid sample preparation workflows.

Learn More

Frequently Asked Questions

Common questions about castable mounting

When should I use castable mounting instead of compression mounting?

Castable mounting is ideal for heat-sensitive materials that cannot withstand the high temperatures (300-350°F) used in compression mounting. This includes soft metals, plastics, electronic components, and materials with different thermal expansion coefficients. Castable mounting also excels at encapsulating irregular shapes, porous materials requiring vacuum impregnation, and samples needing transparent mounts for reflected/transmitted light microscopy. While castable mounting takes longer to cure (8-24 hours vs. 5-10 minutes), it provides gentler treatment and better infiltration for delicate or complex specimens.

How do I choose between epoxy, acrylic, and polyester resins?

Epoxy resins offer the best edge retention, hardness, and minimal shrinkage, making them ideal for most metallographic applications and porous materials. They provide superior adhesion and are less prone to chipping during grinding. Acrylic resins cure faster than epoxies and offer good clarity for transparent mounts, though with more shrinkage and lower hardness. They're excellent for routine work and heat-sensitive samples. Polyester resins are the most economical option with fast curing times, but have the highest shrinkage and lowest edge retention. Choose based on your sample requirements: epoxy for critical edge retention, acrylic for speed and clarity, polyester for non-critical routine mounting.

How can I prevent voids and bubbles in castable mounts?

Preventing voids requires attention throughout the mounting process. Mix resin and hardener slowly and thoroughly to minimize air entrainment. For porous specimens, use vacuum impregnation to draw resin into voids - pull vacuum for 30-60 seconds, then release to allow atmospheric pressure to force resin into the sample. Avoid over-vacuuming which can cause the resin itself to degas. Preheat resin, hardener, and specimens to 85-95°F to reduce viscosity and improve flow. Pour resin slowly down the side of the mold rather than directly onto the specimen. For critical applications, use pressure mounting systems to eliminate bubbles completely. Clean and thoroughly dry specimens before mounting to prevent moisture-related voids.

What are the differences between vacuum, pressure, and UV mounting methods?

Vacuum mounting uses negative pressure to remove air from porous specimens and draw low-viscosity resin into voids, ideal for powder metallurgy, sintered parts, and composite materials. Pressure mounting applies positive pressure (typically 40-60 PSI) during curing to compress bubbles and force resin into fine pores, producing void-free mounts with superior edge retention. UV mounting uses ultraviolet light-activated resins that cure in minutes rather than hours, offering the speed advantage of compression mounting without heat exposure. UV resins are excellent for heat-sensitive samples and transparent mounts, though they typically cost more than conventional resins. Many labs use vacuum for impregnation followed by pressure or UV for final curing to achieve optimal results.

What curing time and temperature should I use for castable resins?

Most epoxy resins cure in 8-12 hours at room temperature (70-75°F), though full hardness may take 24 hours. Curing can be accelerated by heating to 90-100°F for 2-4 hours, but avoid excessive heat which can cause bubbling or cracking from exothermic reactions. Acrylic resins typically cure faster (4-8 hours) but generate more heat during polymerization - submerging molds in a water bath during curing helps dissipate heat and reduce odor. Polyester resins cure fastest (2-4 hours) but also generate the most exothermic heat. Always follow manufacturer recommendations for hardener ratios, as too much hardener accelerates curing but increases heat generation and can cause defects. For best results, cure at controlled room temperature and allow mounts to cool completely before grinding.

How can I achieve optimal edge retention with castable mounting?

Optimal edge retention starts with proper resin selection - epoxy resins provide the best edge retention due to their superior hardness and minimal shrinkage. Ensure specimens are completely clean and dry before mounting, as contaminants can prevent proper adhesion. Use vacuum impregnation for porous materials to fill subsurface voids that could cause edge rounding. Apply pressure during curing (40-60 PSI in an autoclave or pressure vessel) to maximize resin density and minimize voids at the specimen interface. Cure at controlled temperatures to avoid thermal shock and ensure complete polymerization. Consider using filled resins (like glass-filled acrylics) which provide better support for soft materials. For critical edge retention applications, epoxy resins cured under pressure consistently outperform other castable mounting methods and approach the edge retention quality of compression mounting.



Shop Online