In every epoxy project, you'll progress through 5 core phases, eahc of which must be carefully performed to achieve the ideal result. Though most of them are relatively short and straightforward, they're all essential to the process.

In this article, we'll talk about some common but easily avoidable mistakes than many newer epoxy users make in their earliest resin endeavors. By learning how to recognize these mistakes and then taking efforts to avoid them, you'll have a much better chance of achieving that desirable crystal-clear epoxy cure.

The Epoxy Process: 5 Core Phases

Every epoxy goes through at least 5 core phases, with some having additional steps depending on the type of project and the creator's goals.

These phases are:

• Acquiring Epoxy—More important than most realize. The quality of epoxy you use greatly affects the potential of your project. Low-cost budget-brand epoxy is far less likely to cure to a crystal-clear finish than something of higher quality.
  
  
• Measuring an Epoxy Batch—Accurate measuring is essential to getting a clean blend that will cure strong and clear.
  
  
• Mixing an Epoxy Batch—That's what this article is about. Proper mixing will ensure you don't end up with a finish filled with air bubbles and other types of blemishes.
  
  
• Pouring the Epoxy—Pouring is super simple, but there's still room for error. Getting it right is important.
  
  
• Letting the Epoxy Cure—The final and easiest step is also the one new users slack on the most. Curing is mostly hands-free, but it's super important to provide a good environment for the curing to take effect undisturbed.

Below, we'll be discussing Core Phase 3: Mixing an Epoxy Batch. This phase comes right after measuring your epoxy components, and is probably the easiest phase to make mistakes on.

But with the advice we'll be giving below, you'll be more than ready to produce your own smooth epoxy blends ready for pouring!

5 Big Epoxy Mixing Errors to Watch Out For

Getting a perfect epoxy blend when mixing is achievable even when you're not especially familiar with resin. There's a handful of things that tend to go wrong for people who aren't paying close attention.

Here are the 5 epoxy mixing errors we'll be discussing below:

1. Applying too much force when mixing.
2. Using a power drill for low-volume batches or lifting the bit too high in high-volume batches.
3. Mixing the epoxy components for insufficient time.
4. Mixing the epoxy components for excessive time.
5. Reusing a mixing container or using a dirty container for mixing.

We'll start from the top, with number 1.

Mixing Error #1: Applying Too Much Force When Mixing

Perhaps the most common mixing issue—and thus first on our list—is simply applying too much force during the process.

Mixing Too Hard Generates Air Bubbles

When mixing a resin batch with too much force, there's a high chance of pulling in air from outside the epoxy. This air becomes trapped within the epoxy, forming air bubbles throughout the resin batch.

While air bubbles can be removed later on in the project, if there are too many, it sometimes becomes difficult or even impossible to expel them all. For this reason, it's important to avoid putting more force than necessary. Most epoxy resins have a medium-to-low level of viscosity, meaning they put up some resistance to stirring but don't usually require strenuous efforts.

When present, air bubbles can spoil the beautiful aesthetic of cured epoxy, making it look murky or dull. In abundance, they call also negatively impact the durability and physical consistency of the epoxy finish. In the worst cases, you can end up with a finish with soft/weak spots.

Mixing Speed Matters, Too

Another thing to avoid when mixing is the speed at which you stir the resin. For smaller batches, most people use ordinary stir sticks. These are not only adequate but generally effective at producing a clean blend with any contamination.

When using these, it's good to maintain a smooth, consistent speed that isn't too fast. One rare issue that can occur from mixing epoxy at high speed is that it hastens the heat generating reaction that causes the epoxy to cure. If this happens before it's even been poured onto the substrate or mold, it can lead to an incomplete bond with the substrate or an unreliable finish with less durability in some areas.

How to Avoid This Problem

• Mix your resin smoothly and carefully.
• Don't apply too much force, and be careful about moving too fast. For most users this won't be an issue, as there's a natural flow to the mixing that people tend to settle in.

Mixing Error #2: Using a Power Drill for Low-Volume Batches or Lifting the Bit Too High in Large Batches.

Second on our list of mistakes is improper use of a power drill (with accompanying mixing bit).

There are 3 causes for problems in this regard:

• Using a power drill to mix a batch of epoxy that is too small.
• Listing the drill bit too high while mixing a suitably large batch.
• Running the drill at a high speed setting.

The number one problem resulting from these mistakes is the creation of air bubbles within the epoxy batch. Because power drills are so forceful, they can easily pull in air when used incorrectly. This air can then become suspended and manifest as air bubbles which remain in the epoxy even after curing.

For the first two issues, the cause is the drill simply being too close to the surface. A small batch doesn't go as deep. A large resin batch may have more depth, but that also doesn't matter if the drill is held too high in the container as it blends.

For the speed setting issues, though, the problem is that, regardless of how deep the bit is, it's possible to pull in air with strong enough spin.

How to Avoid This Problem

• Only use a power drill on large batches—somewhere around 1 gallon (combined).
• Don't go above a medium speed setting on your power drill when mixing.
• For smaller batches, use stir sticks to blend it manually.

Mixing Error #3: Mixing the Epoxy Components for Insufficient Time

The third common mistake is insufficient mixing of your epoxy batch.

If epoxy resin isn't mixed thoroughly, the components won't be uniformly distributed. This inconsistency can lead to uneven pouring and residual resin remaining in the mixing container.

Moreover, any improperly mixed epoxy that does make it onto a substrate or into a mold may not cure properly, resulting in soft or sticky spots on the finished surface.

While it's possible to correct these sticky spots by removing them and applying a fresh batch of epoxy, this approach requires additional effort and can raise the overall cost of the project.

How to Avoid This Problem

• Be sure to fully mix your resin batch before applying it.
• Read the mixing instructions fully for your chosen resin. All good brands of epoxy should include a set of detailed instructions for each step of the process.

Mixing Error #4: Mixing the Epoxy Components for Excessive Time

In contrast to the previous error in the list, our 4th mistake is overly mixing your epoxy resin. This one is less likely to happen, but it definitely can and is worth bringing up.

Each type of epoxy has a specific time frame for optimal mixing, and exceeding this period can lead to complications during both the application and the final results of your project.

Overmixing can cause the mixture's temperature to rise due to the exothermic reaction between the resin and hardener. This increase in temperature can speed up the curing process, consequently reducing the pot life of the mixture. A reduced pot life means you have less time to handle the resin, apply it, and adjust it on your project before it begins to set.

Furthermore, excessive mixing might lead to the epoxy starting to cure within the mixing container itself, which not only wastes materials but also may result in the epoxy becoming too thick or hard to manipulate before application. This premature curing can complicate the application process and often leads to a suboptimal finish, characterized by an uneven surface or inadequate adhesion to the substrate.

How to Avoid This Problem

• When mixing, be thorough but efficient.
• Follow the included instructions for the brand of epoxy you're using.

Mixing Error #5: Reusing a Mixing Container or Using a Dirty Container for Mixing

Last on our list is the easiest mistake to avoid making.

Many epoxy users try to reuse mixing containers for convenience or to save money. However, we generally advised against reusing containers for additional batches of epoxy resin, as this can lead to contamination and result in improper curing.

Leftover Epoxy Contaminates Fresh Batches

After mixing and pouring an epoxy batch, there's often residue still in the container, which may have partially cured or failed to react. Even small amounts of this residue can disrupt the curing process of a new batch, potentially causing uneven curing. This may result in some areas of the resin mixture remaining tacky or not hardening fully, which compromises the strength and integrity of the finish.

Moreover, remnants of partially cured resin can introduce impurities and air bubbles into the new mixture, affecting both its clarity and structural integrity. These complications are especially detrimental in projects where a clear, smooth finish is crucial, such as in casting or coating applications.

Additionally, the presence of hardened resin fragments can cause physical defects in the final product, leading to bumps or irregularities on the surface.

How to Avoid This Problem

• Use a new container for every batch of epoxy you mix.

Primaloc Epoxy: Premium Epoxy for Premium Results

With our premium Bar & Table Top Epoxy and our Deep Pour Epoxy, Primaloc gets the job done. Our epoxy resins are premium-grade, with high performance in every category, including:

• Unmatched Strength: A Primaloc finish won't buckle, even under high pressure.
• Long-Lasting Resilience: Primaloc epoxy lasts for many years with minimal care, and can endure high-traffic environments with ease.
• A Crystal-Clear Coating: With its pristine, transparent appearance, looking at a cured Primaloc coating is like peering through a window.

Epoxy resin can be beautiful, strong, and long-lasting—which is why you shouldn't compromise on quality. With Primaloc Epoxy Resin, you get the ultimate finish in durability and visual appeal.

Protect your surfaces by giving them a rock-solid epoxy finish. Choose strong. Choose reliable. Choose Primaloc.