phenol formaldehyde (bakelite resin)

What about http://en.wikipedia.org/wiki/Polytetrafluoroethylene, i.e. 'Teflon'?

first off, what are you using as a release agent? What temperature are you cooking the part at? There are literally 100's of these resins so, it makes a difference.

Release agents:

try the Frekote 800 you might find it helps. If your already using something similar. Look at some of the PVD coatings, cost is a factor pretty quickly on some of them. PVD (diamond) and DLC (Diamond like carbon) seem to work very well and have very low surface tension.

Coatings:

Check the web site for: General Magnaplate I would look at the HTR coating. They have several that might work well for you.

Besides a good release agent, Any sharp edges of the holes (or marks in the mold) will have a tendancy to trap material. The hole inside corners should be slightly rounded and polished smooth to a high gloss.

Very true, sharp corners are real part grabbers. Many times if your injection molding the parts you would use pusher pins in the holes. Also if you can take a little more draft in the holes this will help. The radius at the top edge and bottom of the pocket will help, the bigger the better.

Can you post or send a link showing the part or mold? This would help us help you.

Scooter

Try using less resin and lower the temperature.

I use a light coat of silicone oil from an aerosol can.

Bill Morrow

Silicone can be a killer depending on what the end use may be. Also will have an effect on everything else in the plant. Silicone will go everywhere.

You may not need a release agent as much as you do a slip agent in the material. Work with you resin supplier to be sure that you have the right add-pack for your application.

For injection molding, zinc staerate was a good one. I dont know for thermosets.

if the product is painted the silicones are useless. The one part polymerized releases work much better if paint is involved particularly if the molding is done in a hot mold, which is almost required for phenolics/bakelites.

When I was a kid we use to use an aluminum plate that came from a glass department store door. It had the word push on it. We used to use it camping to make pancakes on and didn't need anything to keep the pancakes from sticking.