remolding

Remolding is the process of reshaping a material by forming it in or around a new mold after an initial forming step. It is used to alter shape, correct defects, or produce multiple variants from a batch of material. Remolding can involve reheating a material to regain plasticity, or reworking a solid object through pressure, cutting, or additive methods.

In plastics, remolding is common with thermoplastics, which soften when heated above their melting or glass transition temperatures and can be reshaped and cooled to set again. Thermosetting plastics are harder to remold after cure, though some systems allow remelting under specific conditions. In metals, remolding is achieved through processes such as hot forging, stamping, or casting, often after initial shaping and at elevated temperatures. Ceramics and composites may be remolded by rewetting and re-forming or by debinding and sintering, depending on material type.

Applications include part repair, design optimization, recycling of scrap, and rapid prototyping. In manufacturing, remolding enables part variation without new molds and can reduce waste by reclaiming rejected parts or sprues. In art and sculpture, remolding allows iterative shaping and testing of forms.

Key considerations include material properties after reprocessing (strength, stiffness, color), dimensional accuracy, surface finish, and potential degradation from repeated heating. Process parameters—temperature, pressure, dwell time, and mold design—significantly influence outcomes. Safety, energy use, and environmental impact are also considered in industrial remolding.