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JI Proprietary Putty Patterns

Proprietary Putty Patterns

  • Strong wooden substructure, foam, fiberglass and in-house engineered putty
  • Machined to specific tolerances
  • Extremely accurate and very fast turn-around at an economical cost
  • Easy-to-sand surface can be finished to 80 grit or given a machined primer surface and sanded to a finer finish.
  • Male or female shapes are available depending on application and geometry provided.
  • Designed for room temperature applications, but can be modified to withstand temperatures up to 180ºF
  • Primer surface option available
  • Laser tracking and vacuum integrity options available

Block Foam Patterns & Wood Patterns

  • Machined pattern fabricated out of block foam, MDF or modeling board.
  • Block foam allows for the maintenance of higher tolerances and can reach higher curing temperatures than the JI proprietary putty patterns
  • Medium Density Fiberboard (MDF) wood is stable at higher temperatures than putty, however the surface finish may be rougher.
  • MDF is also a suitable material for casting patterns.
  • Foam patterns can also be provided with a primer finish.
  • A wide variety of foam materials and densities are available depending on your application.

Short Run Molds

Using JI’s putty material system, we make short run molds for one-off or short-production production runs. By shipping in segments and assembling onto a steel frame, there is virtually no limit to the size of the part.

Cold Molded Tooling

  • Cold Molded Tools start with a rigid steel reinforced space frame as the base.
  • Wooden station frames are attached to the frame to form the basic shape.
  • Wooden battens are planked between the wooden station frames.
  • Thin sheets of plywood are molded over the wooden battens to create a wooden face-sheet.
  • A Fiber Reinforced Plastic (FRP) vacuum barrier layer is then applied to the wooden face-sheet.
  • JI proprietary putty medium is sprayed onto the FRP layer before machining surface to the final net contour.
  • Surface finished to the customer specified requirement.
  • Verified for both vacuum integrity and surface contour conformity.
  • Can be built in multiple sections and installed at the customer's facility allowing you an unlimited range of sizes for your tooling application.
  • Very accurate and stable; can be used for multiple mold prints with minimal maintenance and repair between cycles.

Fiber Reinforced Plastic Tools

Molded from machined patterns; built to customer specifications. Composite consists of varying thickness fiberglass layers, a rigid balsa or foam core, and a durable tooling gel-coat finish. We have engineered FRP mold systems up to 220 feet in length.

250° Composite Tools

Carbon fiber or fiberglass composite tools, surface finishes optional depending on customer needs.

Cast 250° Tool

Also referred to as molded or transfer tools

Cast 250° Tool

  • Infused on a highly accurate machined pattern
  • Use Temperature: 250° F
  • Tolerances: up to ± .010"
  • Support: Steel tubing or composite egg-crate

Machined 250° Tool

Machined 250° Tool

  • Machined tools provide higher accuracies than cast
  • Includes laser tracking reports and vacuum verification
  • Use Temperature: 250° F (modifications can provide a 300° use temperature)
  • Tolerances: ± .005" - .015"
  • Support: Steel or composite egg-crate

350° Composite Tools

Our 350° tools are a carbon fiber or fiberglass tool infused with an epoxy resin formulated to customer specifications. These 350° tools are available in two variations: cast and machined. Machined tools allow for the maintenance of higher accuracies. These 350° tools are provided with laser tracking and vacuum verification is performed to ensure conformity.

Cast 350° Tool

Cast 350° tools are infused on a highly accurate machined pattern and produce an accurate tool with optional surface finishes.

Cast 350° Tool

  • Use Temperature: 350° F
  • Tolerances: up to ± .010"
  • Support: Composite egg-crate

Machined 350° Tool

Machined 350° tools are infused on a pattern and machined on its support structure with our 5-axis mills.

Machined 350° Tool

  • Surface is extremely accurate and finished to exact specifications
  • Use Temperature: 350° F
  • Tolerances: ± .005" - .015"
  • Finish: Machined; 32 rms typical
  • Support: Steel or Composite egg-crate

Metal tools and parts

For high pressure, high volume processes

Invar Metal

  • Steel
  • Aluminum

Composite Cauls

Composite Caul

  • Use Temperature: RT, 250° F, & 350° F
  • Materials: Carbon, Fiberglass, and Hybrid’s
  • Processing: Infused or Pre-Preg
  • Mastering: Cast off low temp patterns and post cured. Or, optional high temp imide based composite caul systems produced from high temp composite or steel molds.
  • Finish: Machined; 32 rms typical, as high as 8 rms


Janicki metal tools are your solution if your project requires high production runs. Using metals selected to match the CTE’s of your project, we will fabricate long-lasting hard tooling.

Machined metal parts are a growing segment of the Janicki product line. Our large-scale, high-precision Janicki mills can handle parts or part-segments up to 100 ft x 20 ft x 8 ft.

Steel composite hybrids are a Janicki core capability. These tools are quick to produce because the face sheets and frames are made simultaneously. Our experienced process engineering team can adjust CTE’s on these tools to meet specific needs.

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