Tooling Manual - Reichhold

7/31/2019 Tooling Manual - Reichhold

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Scope of this Manual

A revolutionary new polyester material and process technique

has been developed that produces a production and

process-ready composite tool in typically 80% less time than

conventional polyester tools. These tools, used in the production

of open mold fiberglass hand lay-up/spray-up and resin transfer

molding (RTM) parts, have for years required weeks of

painstaking, labor intensive, hand lay-up of one or two layers ata time of resin-impregnated fiberglass mat reinforcement.

This new material represents a breakthrough in reducing the

lead time from concept design to part production.

This manual documents the proper techniques and procedures in

constructing composite molds made from Polylite ProfileTooling

Polyester Resin and demonstrates the cost effectiveness of the

resin compared to traditional polyester resins.

Introduction

Intended Audience

Both pattern and tool makers will find this manual useful in the construction of composite tools and prototype parts.

Part Detailers, Industrial Designers and Engineers will also find the manual informative in designing parts that are truly

production ready.

Reichhold

Reichhold is the worlds largest supplier of unsaturated polyester & vinyl ester resins used by the automotive, boat-building,wind energy, industrial, corrosion, flame retardant, leisure and tool making industries. For further information about

Reichholds product offerings contact your nearest Reichhold representative.

Copyright 2008, Reichhold Inc.All rights reserved.


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Table of Contents

A1 Polylite Profile System Advantages

A2 System Comparison

B1 Resin Compound Formulation

B2 System Recommendations

B3 Approved Application Equipment

B4 Approved Fillers | Approved Glass Reinforcement

C1 Resin Compound Mix Proportions

C2 Promoter to Resin Mix

C3 Promoter Levels Versus Gel Time and Temperature

C4 Initiator Levels Versus Gel Time and Temperature

C5 Slave Arm Recalibration

D1 Tool Construction Technology

D2D9 Tool Construction TechnologySteps

E1E11 Trouble shooting

F1F2 Typical Polylite Profile Resin Properties

F3 Typical Polylite Profile Resin Physical Properties

G1G10 Technical Tips

H1H2 Casting

I1 Packaging / Safety / Quality / Storage

I2 Polylite Profile Distributors

I3 Corporate Headquarters


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Polylite Profile 33540 Series is a non-promoted, non-thixotropic,

unsaturated polyester laminating resin. Polylite Profile 33540

Series is suitable for construction of FRP tooling. The resin is

formulated for room-temperature curing with Superox 46750

peroxide initiator and is to be used with specific alumina

trihydrate fillers. Polylite Profile 33540 Series must be promoted

with Reichhold 46559 cobalt-based promoter solution prior to

initiation.

Polylite

Profile System Advantages

A1-a

33540 Series

FEATURES BENEFITS

Tools can be built in 80% less time Significantly reduces labor costs

Production start-up time reduced

Makes prototype tools rapidly and economically

Low Shrinkage Tool reproduces master exactly

Resulting tool is stress free

Print through and surface distortion eliminated

Pre-release potential minimized

Tool post-finishing reduced

Rapid Barcol hardness development Tool demolds faster

Visual color change during cure Built-in quality control indicator

Fillable to 50% with ATH Lower composite cost

Increased composite stiffness

Improved heat transfer

SPC/SQC Controlled Consistent performance ba tch to batch


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Polyilte Profile 33541 Series is a promoted, non-thixotropic,

unsaturated polyester laminating resin. Polyilte Profile 33541


formulated for room-temperature curing with Superox 46750

peroxide initiator and is to be used with specific alumina

trihydrate fillers.

Polylite

Profile System Advantages33541 Series

A1-b

FEATURES BENEFITS






Print through and surface distortion eliminated

Pre-release potential minimized




Fillable to 50% with ATH Lower composite cost



Pre-Promoted No additional promoters needed



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Polyilte Profile 33542 Series is a promoted, thixotropic,

unsaturated polyester laminating resin. Polyilte Profile 33542


formulated for room-temperature curing with Superox

46709 peroxide initiator or other approved peroxide initiators.

Polylite

Profile System Advantages33542 Series

A1-c

FEATURES BENEFITS






Print through and surface distortion eliminatedPre-release potential minimized




Pre-filled with ATH Lower composite cost



Pre-Promoted No additional promoters needed



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System Comparison33540 Series | 33541 Series | 33542 Series

A2

This chart represents two major areas of benefits using the Polylite Profile Tooling System versus standard resin used in production tooling. A typical tool can be produced at a system cost

savings of approximately 50% compared to conventional laminating resins and tool making methods. The savings is passed on in both labor and materials. In addition to a system cost saving,

a production time savings of up to 80% is also realized by using the Polylite Profile system.

100%

90%

80%

70%

60%

50%

40%

30%

20%

10%

0%

SYSTEM COST TOTAL TIME

I Standard

Non-Filled Resin

I All Polylite Profile

Tooling Systems

System cost is

reduced by 50%with the Polylite

Profile System

Production time

is reduced by 80%

with Polylite

Profile System


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Resin Compound Formulation33540 Series

B1-a

COMPOUND

Polylite P ro file 3 35 40 S er ie s R es in 10 0 pa rt s

Alumina Trihydrate Filler 100 parts

Reichhold 46559 Promoter 0.40.8 parts, based on resin weight

Superox 46750 Peroxide Initiator 1.25 parts, based on resin weight

Fiberglass Roving 1822% of laminate weight

TYPICAL EXAMPLE

When mixing a 55 gallon drum of resin (net weight 300 Ibs), the following formulation should be followed:

Po ly lit e Pr ofi le 33 54 0 Se ri es 30 0 lb s (13 6.08 k g)

Alumina Trihydrate Filler 300 lbs (136.08 kg)

Reichhold 46559 Promoter 1.5 lbs (.680 kg)


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Resin Compound Formulation33542 Series

B1-c

Mix Requirements

Note: Superox 46709 Peroxide Initiatior is not to be mixed into

the resin/filler mix but metered through the chopper gun.

COMPOUND

Polylite Profile 33542 Series Prefilled & Promoted 100 parts

Superox 46709 Peroxide Initiator 1.25 parts, based on resin weight

Fiberglass Roving 1822% of laminate weight

TYPICAL EXAMPLE

When mixing a 55 gallon drum of resin (net weight 300 Ibs), the following formulation should be followed:

Po ly lit e Pr ofi le 33 54 2 Se ri es 30 0 lb s (13 6.08 k g)

Polylite Profile must be agitated or mixed well to ensure even filler distribution. A bunghole mixer is not an

acceptable mixer. A gear driven agitator or similar agitator/mixer for a 55 gallon drum is needed to properly mix

Polylite 33542-25 before use.


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System Recommendations33540 Series

B2-a

EQUIPMENT

Airless, initiator injected spray-up chopper system

Pressurized gun for gel coat application

Air compressor

Mixing tank with mixing blade

Aluminum or plastic serrated roller

Laminate thickness gauge

Gelcoat thickness gauge

Brush

Scales

Graduated cylinder

OSHA approved canister-type respirator for paint and vapors

Face shield or chemical goggles

Impervious gloves

Overalls or paper clean suit

MATERIALS

Polylite Profile 33540 Series, non-promoted, low shrink polyester tooling resin

Alumina Trihydrate Filler

Initiator, i.e. Superox 46750 Initiator

Mold release agent

Tooling gelcoat with appropriate initiator

Continuous fiberglass gun roving or chopped strand mat.

Core material, i.e. balsa wood

Structural support materials, i.e. steel, wood

Reichhold 46559 promoter solution


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System Recommendations33542 Series

B2-c

EQUIPMENT

Airless, initiator injected spray-up chopper system

Pressurized gun for gel coat application

Air compressor

Mixing tank with mixing blade

Aluminum or plastic serrated roller

Laminate thickness gauge

Gelcoat thickness gauge

Brush

Scales

Graduated cylinder

OSHA approved canister-type respirator for paint and vapors

Face shield or chemical goggles

Impervious gloves

Overalls or paper clean suit

MATERIALS

Polylite Profile 33542 Series, promoted, filled, low shrink polyester tooling resin

Superox 46709 Initiator

Mold release agent

Tooling gelcoat with appropriate initiator

Continuous fiberglass gun roving or chopped strand mat.

Core material, i.e. balsa wood

Structural support materials, i.e. steel, wood


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Approved Application Equipment33540 Series | 33541 Series | 33542 Series

B3

MANUFACTURER PRODUCT SUGGESTED SPRAY TIPS SUGGESTED AIR PRESSURE SETTINGS

VenusMagnum H.LS. PG 1116 Portable Chopper 6503 10 psi above non-filled settings

Division of PMC, Inc. P21 Pump (11:1) with Abrasives 6504

1862 Ives Avenue Application Package

Kent,WA 98032

(206) 854-2660

Binks Manufacturing Company 102-2400 Century Spray Gun N/A N/A 9201 West Belmont Avenue Model 105-1 326 Portable Chopper

Franklin Park, IL 60131-2887 B6-D (20:1) Pump

(708) 671-3000

Graco Composites Equipment INDy or Formula System LPA2-147-5240 (Airless Tip) Resin 6070 psi

8400 Port Jackson Ave. NW Pump (11:1) LPA2-147-5250 (Airless Tip) Atomized Air 3540 psi

North Canton, OH 44720 B-410/B-510 Chopper 23005-J5 (Non-Atomized Tip) AAC 60 psi

330-494-1313 INDy or Formula Dispense Gun 23005-J4 (Non-Atomized Tip)

with Air Assist Containment

(Internal or External Mix)


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Approved Fillers | Approved Glass Reinforcement33540 Series | 33541 Series | 33542 Series

B4

Approved Fillers Approved Glass Reinforcement

PRODUCT MANUFACTURER

A-208 Alumina Trihydrate R. J. Marshall Company

(Not used with 33452 Series) 26776 W.Twelve Mile Road

Southfield, Ml 48034-7807

(800) 338-7900

PRODUCT MANUFACTURER

Hybon 700 HTX PPG Industries, Inc.

MPM 112 o z c ho pp ed s tr an d m at On e P PG P la ce

MPM 34 oz chopped strand mat Pittsburgh, PA 15272

(412) 434-3250

ME-3021 Roving Ow ens Corning Fiber glass Corporation

Fiberglass Tower

Toledo, OH 43659

(419) 248-8000


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Resin Compound Mix Proportions33540 Series | 33541 Series

C1

This chart provides a reference a point for determining material mix proportions of Polylite Profile Tooling System and Alumina Trihydrate. For example, 300 lbs of Polylite Profile will require

300 lbs of Alumina Trihydrate filler.

1000

900

800

700

600

500

400

300

200

100

0

10 (4.54)50 (22.68)

50 (22.68)

250 (113.40)

250 (113.40)

300 (136.08)

300 (136.08)

500 (226.80)

500 (226.80)

10 (4.54)

I Polylite Profile

33540 and 33541 Series

I Alumina Trihydrate lbs (kg)


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Promoter to Resin Mix33540 Series

C2

R esin Weigh t lbs ( kg ) 10 ( 4.54 ) 45 ( 20 .4 3) 25 0 ( 113 .4 0) 3 00 ( 13 6.08 ) 45 0 ( 204 .1 2)

Promoter Solution @ 0.4% gm (ml) 18.2 (19.5) 81.7 (87.9) 454.0 (488.2) 544.8 (585.8) 817.2 (878.7)

Promoter Solution @ 0.5% gm (ml) 22.7 (24.4) 102.2 (109.8) 567.5 (610.2) 681.0 (732.3) 1021.5 (1,098)

Promoter Solution @ 0.6% gm (ml) 27.2 (29.3) 122.6 (131.8) 681.0 (732.3) 817.2 (878.7) 1225.8 (1,318.)

Promoter Solution @ 0.7% gm (ml) 31.7 (34.2) 143.1 (153.7) 794.5 (854.3) 953.4 (1,025.2) 1430.1 (1,537.3)

Promoter Solution @ 0.8% gm (ml) 36.2 (39.1) 163.6 (175.6) 908.0 (976.3) 1,089.6 (1,171.7) 1634.4 (1,756.6)

This table will assist in calculating the correct quantity of

Reichhold Promoter 46559 to be added to Polylite Profile

33540 Series resin.

Warning

Care must be taken to avoid direct mixing of any organic

peroxide with metal soaps, amine, or any other polymerization

accelerator or promoter. Violent decomposition will result if

this is not followed.


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Promoter Levels Versus Gel Time and Temperature33540 Series

C3

This chart provides a reference point for determining the level of promoter to be used with a filled Polylite Profile resin system. For example, with an initiator level of 1.25%, Reichhold 46559

promoter level of .45%, will provide a gel time of approximately 18 minutes at 77F (25C).

This chart show the variance temperature has on gel time at varied promoter levels.

80

70

60

50

40

30

20

10

0

0.00 0.20 0.25 0.35 0.40 0.45 0.50 0.75 1.25 1.50

PROMOTER LEVEL %

Initiator @ 1.25% 46750

GELTIME,

MINUTES

90F (31.2C)

77F (25.0C)

65F (18.3C)I

L

L

L

I

I

I

I

I

I

I

L

L

L

L

L

L

+

+

+

+

+

+


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Initiator Levels Versus Gel Time and Temperature33540 Series

C4

This chart provides a reference point for determining the level of initiator to be used with a filled Polylite Profile resin system. For example, an initiator level of 1.25% (based on resin weight),

at 65F (18.3C) will provide a gel time of approximately 39 minutes.

This chart shows the variance temperature has on gel time at varied initiator levels for one type of system.

80

70

60

50

40

30

20

10

0

0.50 0.75 1.00 1.25 1.75 2.5 3.5

I N I T I A T O R L E V E L %

GELTIM

E,

M

INUTES

90F (31.2C)

77F (25.0C)

65F (18.3C)

L

I

+

I

I

I

I

L

L

L

L

L

L

+

+

+

+

+

Promoted @ .45% 46559


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Slave Arm Recalibration33540 Series | 33541 Series | 33542 Series

C5

R es in/ Fi ller Ra tio Slav e- Ar m S et ting

% Superox 46750 (33540 and 33541)

% Superox 46709 (33542)

1:1 0.75 1.14

1:1 1.00 1.51

1:1 1.25 1.90

1:1 1.50 2.30

1:1 1.75 2.70

This table provides general guidelines for the pump/slave-arm recalibration.Most application equipment dispenses materials using positive

displacement pumps and mechanical slave-arms to ensure

accuracy. Because peroxide initiator slave-arm adjustments are

typically set for non-filled materials, recalibration is required to

ensure proper metering.

Note: Accurate equipment calibration should always be

performed prior to use. This should be accomplished by

independently dispensing, collecting and weighing the resincompound and peroxide initiator.

Warning

Do not use Superox 46750 with the Polylite 33542 Series


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Tool Construction Technology

33540 Series | 33541 Series | 33542 Series

D1

Use serrated rollers and brushes to remove air and thoroughly work the resin into the reinforcement.

Several layers of chopped material or specialized reinforcement can be added to the laminate depending upon

the requirements of the application. Again, as in hand lay-up, structural core materials can be incorporated within

the laminate construction.

The spray-up process

As in the hand lay-up process, a release agent followed by a

sprayed-on gelcoat is first applied to the master. When the

gelcoat has cured according to the manufacturers instructions,

the spray up process can begin. Prior to applying the filled

tooling system, Reichhold recommends the application of a skin

coat using our premium Hydrex resin. This skin coat should be

applied at a minimum 0f 1.52 ounces of CSM or its equivalent.

The next step in the spray-up process is to apply an initiated

compound mist coat (no glass) of the tooling resin followed by

spraying glass fiber reinforcement and resin compound through

a chopper gun. This gun simultaneously chops a continuous

fiberglass roving into suitable length (typically 112 inches) and

mixes initiator into the sprayed and filled resin compound.

Shorter glass fibers (12 inch ) can be used with smaller or

complicated tools to minimize glass bridging in sharp corners.

Additionally, long glass fibers ( 2 inches) can be used in flat tools

or in tools that require higher strength.


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Tool Construction TechnologySteps

33540 Series | 33541 Series

D2-a

Mixing Guide per 100 lbs of Resin

Polylite Profile 33540 and 33541 series 100 lbs

Alumina Trihydrate Filler 100 lbs

Reichhold 46559 Promoter (use with 33540) 0.5 lbs

Superox 46750 Initiator 1.25 lbs

(use with 33540 and 33541 series only)

Recommended Clean-up of Spray Equipment

Regardless of the equipment used, the pumping system should be periodically flushed. It is recommended that clean,

unfilled neat resin be used for this process. Solvents should not be used as the initial flushing agent. Flushing first

with neat resin will remove or purge the filled resin from the pump. Then, if required, solvent can be used to flush the

pump clean. To ensure good working conditions, follow manufacturers equipment recommendations for clean-up.

STEP 1MASTER PLUG

A. Construct master plug and finish to exact dimensions and surface smoothness

B. Apply appropriate release agent to the surface (following manufacturers directions exactly).


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33542 Series

D2-b

Tooling System Components

Polylite Profile 33542 Series

Superox 46709 Initiator

Recommended Clean-up of Spray Equipment

Regardless of the equipment used, the pumping system should be periodically flushed. It is recommended that clean,

unfilled neat resin be used for this process. Solvents should not be used as the initial flushing agent. Flushing first

with neat resin will remove or purge the filled resin from the pump. Then, if required, solvent can be used to flush the

pump clean. To ensure good working conditions, follow manufacturers equipment recommendations for clean-up.

STEP 1MASTER PLUG

A. Construct master plug and finish to exact dimensions and surface smoothness



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33541 Series

D3-b

Safety Requirements

Always wear a face shield or chemical goggles along with

impervious gloves to prevent skin contact with chemicals.

A canister-type respirator must be worn to prevent the inhalation

of vapors or spray mists.

STEP 2RESIN COMPOUNDING

A. The quantity prepared should be a sufficient size to be used in an eight hour period. Filler settling may occur;

therefore, periodic or constant low speed agitation is suggested. Should the mix be undisturbed for periods

greater than four hours, remixing is recommended.

B. Mix at moderate speed for 2 minutes or until thoroughly mixed. Resin should have uniform color throughout mix.

C. Increase agitation to high speed and add alumina trihydrate filler at a steady rate. Blend filler until a 1:1 ratio of

filler to resin is achieved. Scrape sides of the container to prevent filler from hanging to container sides. Refer tothe chart on page C1 for mix proportions. See Figures 3 and 4.

D Continue agitation at high speed for 10 minutes then agitate at low speed for 10 minutes to allow entrapped

air to escape.

E. Fill spray gun catalyzer system with Superox 46750 peroxide initiator. Make sure tank is clean to

prevent contamination.

Figure 3 Figure 4


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33542 Series

D3-c

Safety Requirements

Always wear a face shield or chemical goggles along with

impervious gloves to prevent skin contact with chemicals.

A canister-type respirator must be worn to prevent the inhalation

of vapors or spray mists.

STEP 2RESIN COMPOUNDING

A. Remove the lid of t he 33542 Series drum. Attach an appropriate mixer.

B. Turn mixer on and agitate for 2030 minutes

C. Fill spray gun catalyzer system with Superox 46709 peroxide initiator. Make sure tank is clean to

prevent contamination. See Figures 5 and 6.

Figure 5 Figure 6


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D4

STEP 3PRE-APPLICATION QUALITY CONTROL

A. After charging and adjusting the dispensing equipment, test to ensure that the proper gel and cure

characteristics are achieved.

B. Make a test laminate of equivalent cross-sectional thickness simulating the tool (120 mils minimum). Maintain a

glass reinforcement content of 18-22% by weight. One and one half inch (38.1 mm) chopped glass is typically

used, but this may vary to suit the application and end use requirement. See Figures 79. Make sure test panel is

moved to a table for curing.

C. If required, adjust the levels of either Superox 46750 (if using 33540 or 33541) or Reichhold 46559 promoter

(if using 33540 or 33541) or Superox 46709 (if using 33542) to achieve the desired gel and cure time.

Refer to pages C2 and C4 for assistance.

D. Test laminate should reach a Barcol hardness of 25 within approximately 60 minutes after gelation.

STEP 4GEL COAT

A. Spray on t wo or three wet passes of tooling gelcoat to develop a 30-40 mil (0.76-1 .02 mm) thickness and allow

to cure to a tacky feel. See Figures 10.

B. Follow all gelcoat manufacturers recommendations for handling and application.

Figure 7

Figure 9 Figure 10

Figure 8


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D5

Paste Mix Formulation

Resin Compound 40% (volume)

Fumed Sil ica/Mi lled Fibers 60% (volume)

Superox 46750 Init iat or 1.25% ( weight)

(use with 33450 and 33541 only)

Superox 46709 Init iat or 1.25% ( weight)

(use with 33452 only)

STEP 5FILLER PASTE APPLICATION (OPTIONAL)

A. Apply a skin coat, using Hydrex 33390 with a minimum of 1.52 0z of CSM.

B. If the master has sharp 90 fillets or interior corners, fumed silica and/or milled fibers can be mixed with the resin

compound to form a paste. This paste can be applied to the back side of the skin coat. The paste is catalyzed

with Superox 46750 Peroxide Initiator (if using 33540 and 33541), or Superox 46709 (if using 33542) thoroughly

mixed and applied to the radius areas. This will minimize problems with air entrapment in the radii caused by

glass bridging. Milled fibers add additional strength to the mixture.

The filled resin paste should be applied to a maximum cross-sectional thickness of 120 mils (3.05 mm). Do not

allow the paste to cure before proceeding with the lamination. See chart Initiator Levels Versus Gel Time and

Temperatureon page C3 for gel time information. See Figures 1112.

STEP 6LAMINATE APPLICATION

A. Spray a mist coat of resin compound to an approximate thickness of 10 mils (0.25 mm). This should completely

wet the surface. Only mist an area which can be worked prior to gelation. See Figure 13

B. A brush may be used to assist with resin coverage and removal of entrapped air.

C. Apply a fiber-reinforced resin layer to approximate thickness of 3045 mils (0.76-1.14 mm) accomplished in one

or two passes. See Figure 14.

Figure 13

Figure 12

Figure 11

Figure 14


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D6

Warning

Polylite Profile has been formulated to resist drainage and

slippage on vertical surfaces when applied to a laminate

thickness of 120-130 mils (3.05-3.30 mm). If laminate

applications gel and harden but fail to achieve the characteristic

light color, STOP the construction process and consult the trouble

shooting guide or consult your Reichhold representative.

STEP 7ROLL OUT

A. Remove all entrapped air with a brush or roller after each pass. Carefully inspect and remove air voids in laminate

before proceeding to the next laminate application. Laminate applications must have a minimum thickness of

120 mils (3.05 mm) prior to gel and cure. See Figures 1517.

B. Work out all entrapped air.

Figure 15 Figure 16

Figure 17


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D7

STEP 8CURE

A. Allow the exotherm of each 120 mil (3.05 mm) laminate to subside before proceeding with subsequent

applications. See Figure 18. Failure to do so will decrease the working time of subsequent laminations. Because

in-service requirements of tools vary, it may be necessary to apply multiple laminates to achieve the desired

cross-sectional thickness of the completed tool.

B. Scuff sand with 60 grit sand paper, where required, to ensure void-free application of core reinforcement.

C. Repeat Step 6, as needed, to achieve the required composite thickness.

D. After each laminate application, trim excess glass from flange edge of the tool aft er partial cure is reached

STEP 9BACKUP CORE REINFORCEMENT

A. Scuff sand with 60 grit sand paper, where required, to ensure void-free application of core reinforcement.

See Figure 19.

B. Tailor and cut core material to fit.

C. Pre-wet core material with resin compound on down side.

D. Apply 120 mils (3.05 mm) of bed laminate. Applied in multiple wet passes.

Figure 18

Figure 19


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D8

STEP 9BACKUP CORE REINFORCEMENT (CONT)

E. Apply core material to the tool. If using balsa with a scrim back, score with razor knife to aid in conformance

to the bed laminate. Remove entrapped air under core mat. See Figure 20.

F. Allow the core and bed laminate to cure before proceeding. Check for voids under the core and repair as required.

G. Spray resin compound over core material. See figures 21-22.

H. Spray chop over the core material until a total thickness of 120150 mils (3.053.81 mm) is reached.

Achieve this thickness in multiple wet passes.

I. Roll out all entrapped air.

J. Trim excess glass from the flange edge of tool after partial cure is reached.Figure 20

Figure 21 Figure 22


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D9

Note: Workplace temperature, materials temperature, promoter

concentration and initiator concentration will influence the cure

rate of Polylite Profile. A minimum Barcol 934-1 value of 45

should be achieved prior to removing the tool from the master.

STEP 10ADD BACK-UP REINFORCEMENT STRUCTURE

A. Cut and tailor a backup structure as required to maintain proper support.

B. Scuff sand attachment points on the tool as required to ensure a proper fit.

C. Position structure on the tool and attach by spraying chop around each attachment point. See figure 23.

D. Roll out any entrapped air.

STEP 11REMOVE MASTER

A. Allow to cure for a minimum of 24 hours before r emoving the tool from the master.

B. Remove the tool from the master. See Figure 24.

STEP 12APPLY RELEASE AGENT

A. Prepare tool with appropriate release agent. Follow all manufacturers instructions.

Figure 23

Figure 24


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Trouble Shooting

33540 Series

E1-a

CAUSES CORRECTIVE ACTION

1. Resin-rich surface Remove excess resin from laminate surface before applying next layer. Abr ade surface using

60 grit sand paper.

2. Contamination of the laminate surface Remove dust or other contamination from laminate surface before applying next laminate.

3. Laminate under cured Maintain correct promoter and initiator levels.

4 . E xc es si ve l am in at e c ur e Do n ot i nt er rup t la min at io n f or e xt en de d p er io ds o f t im e o r e xp os e n on- co mp le te d p ar ts t o

excessive heat or sunlight.


1. Low resin and/or workplace temperature Maintain work area, master and resin compound temperature of 85F minimum.

2. Low peroxide initiator levels Maintain a minimum level of 0. 8% by volume or 0.6% by weight of Super ox 46750 Peroxide Initiator

based on resin. Recalibrate dispensing equipment.

3. Thin laminate Maintain promoter level of 0.41.0% by weight. Use 46559 promoter

4. Wet filler Replace with dry filler.

Defect: Slow Cure

Description: Laminate takes excessive amount of time to develop hardness

Defect: Delamination

Description: separation of the composite occurring between laminate layers.


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Trouble Shooting


E1-b


1. Resin-rich surface Remove excess resin from laminate surface before applying next layer. Abr ade surface using

60 grit sand paper.

2. Contamination of the laminate surface Remove dust or other contamination from laminate surface before applying next laminate.

3. Laminate under cured Maintain correct initiator levels.

4 . E xc es si ve l am in at e c ur e Do n ot i nt er rup t la min at io n f or e xt en de d p er io ds o f t im e o r e xp os e n on- co mp le te d p ar ts t o

excessive heat or sunlight


1. Low resin and/or workplace temperature Maintain work area, master and resin compound temperature of 85F minimum.

2. Low peroxide initiator levels Maintain a minimum level of 0. 8% by volume or 0.6% by weight of Super ox 46709 or 46750

Peroxide Initiator based on resin. Recalibrate dispensing equipment.

3. Thin laminate Maintain thickness of 120 mils (3.05 mm) for each laminate application.

4. Wet Filler Replace with dry filler (33541)

Defect: Slow Cure

Description: Laminate takes excessive amount of time to develop hardness

Defect: Delamination

Description: separation of the composite occurring between laminate layers.


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Trouble Shooting


E2

FCAUSES CORRECTIVE ACTION

1. Gel coat not fully cured when skin coat is applied Switch to faster curing gel coat. Allow more time for gel coat to cure. Increase work-area

temperature and materials.

2. Long resin gel time allows styrene in skin coat resin to soften gel coat Increase peroxide initiator level in resin. Maintain 1.02.0% based on resin. Increase work area

temperature. Check for moisture in filler. Recalibrate dispensing equipment.

3. Orange peel imprint in tool Replace or refinish master mold.

4. Air voids in skin coat Apply mist coat and roll out air in skin coat.

5. Excessive orange peel during application of tooling gel coat Adjust gelcoat application and/or consult gelcoat manufacturer.


1. Filler content of mix is too high (Does not apply to 33542 Series) Reduce filler content down to 45% minimum through addition of more Polylite Profile 33540 or

33541 Series. Agitate mix to prevent settling of filler.

2 . H ig h g la ss t o r es in r at io In cr ea se r es in l in e p re ssu re , r edu ce c hop pe r s pee d a nd in cr eas e d ia me te r of r es in t ip .

3. Resin from gun does not wet-out chop Adjust spray angle to ensure complete glass to resin overlap. Re-wet laminate with filled resin mix after

each application of laminate.

4. Incompatible glass binder or sizing Switch to glass with a binder and/or sizing with better solubility. Use only recommended reinforcements.

Defect: Poor wet-out / workability

Description: Saturation of glass fibers is difficult

Defect: Orange Peel surface finish

Description: Irregular surface to the gel coat which has the surface texture of an orange


35/64

Trouble Shooting


E3


1. Contamination in resin Inspect resin and air line for contamination (such as oil).

2. A ir voids in skin coat Reduce first fiberreinf orced resin layer to an appr oximate thickness of 2030 mils.

Remove entrapped air before proceeding to the next laminate application. Laminate applications

must have a minimum thickness of 120 mils (305 mm) prior to gel and cure.

Use 14 inch long chop in first 2030 mils of skin coat.

Reduce filler content to 45% by weight.

Run 6 blades in chopperalternate and inch glass in first 20-30 mils of skin coat. Chop one

strand of roving. Adjust chopper motor speed to maintain proper resin to glass ratio. Adjust resin to

glass fan to ensure uniform wet out and composition. Maintain resin compound temperature at

2932 (85 5F). Use brush to assist with wet out.

Roll laminate using brissel type or bubble buster roller. Inadequate mixing of additives during

application. Review mixing procedure described in tooling manual.

3 . Per ox ide i nit ia to r dr op le ts M ak e s ur e t he pe ro xid e i ni ti at or fl ow s to ps when t he t rig ger o n t he gu n i s r ele as ed . .

(bl is te r o ft en c on ta in s l iq ui d wit h a v in ega r od or ) Ke ep gu n t ip cle ar

4. Inadequate mixing of peroxide initiator Adjust or modify mixing capabilities of equipment.Visually inspect laminate to ensure uniform mixing

after initial catalyzation.

Defect: Blisters

Description: Blisters forming on the surface of the part. The blister may or may not contain a liquid.


36/64


37/64

Trouble Shooting


E4-b


1.Poor mixing of the peroxide initiator Adjust equipment to ensure peroxide initiator in uniformly mixing with resin. Check viscosity of filled

resin mix. Ensure dispensing equipment is suitable for filled resin system.

2. Contamination of resin, filler or glass reinforcement Use different filler, glass or resin. Inspect lines and filters for contamination or restrictions. Inspect glass

for contamination and/or moisture content.

3. Improper peroxide initiator used Use only Superox 46750 (with 33541 only) or 46709 (with 33542 only). Use of other peroxide initiators

can inhibit gel and/or cure.

4 . L ow t em per at ur e in wor k ar ea o r of m at er ia ls M ai nt ain a m ini mum t em per at ur e o f 8 5 F

5. Uneven laminate thickness The laminate wil l a lways cure faster in thick and resin-rich areas. To avoid variations in thickness,

the gun operator needs to make long sweeping motions when chopping. Frequently monitor laminate

thickness in various locations on the part. Maintain a minimum thickness of 120 mils (3.05 mm).

Defect: Spotty Cure

Description: Some areas of the laminate will gel and cure faster than other areas. In extreme cases, areas of the laminate may never cure.


1 . E xc es si ve l am in at e t hi ck ne ss Do n ot a pp ly m or e t ha n 1 50 m ils (3.81 m m) of l am ina te i n on e a pp li ca ti on .

2. Glass content is too low Maintain glass content of 1822%.

3. Excessive laminate gel time Maintain proper tempera ture and levels of peroxide initiator.

4. Mist coat too thick Maintain mist coat t hickness to 10 mils (.25 mm) or less, especially on vertical surfaces.

Defect: Sagging (Sliding)

Description: Non-gelled laminate slides down the vertical surface of the master. This causes a ripple to form in the laminate.


38/64

Trouble Shooting


E5


1. Improper application of gel coat and/or mold preparation Follow manufacturers recommendations. Maintain a uniform gel coat thickness of 1830 mils

(0.460.76 mm) dry.


1.Improper rol l-out or excessively thick Rol l out between each 2040 mils (0.511.2 mm) application of chop. Rol l out using moderate

speed and pressure.

2. Drainage from low viscosi ty leaves air voids Review causes under Drainage. See page E6-a

3. High viscosity (Does not apply to 33542 series) Retest filled viscosity. Recalculate resin and filler addition. Maintain 1 to 1 ratio by weight. Reduce filler

content to 45% minimum. Increase filled resin mix temperature to 7080F (21.126.7C). Do not

add additional monomers. Only Polylite 33540 or 33541 Series may be added to restore proper filler-

to-resin ratio.

4 . R es in -s ta rv ed a re as M ai nt ain p ro pe r r esi n m ix -t o- gla ss r at io . P re -wet p ar t wit h fil le d r es in p ri or t o a pp li ca ti on o f la min at e.

5. Short gel time does not allow glass wet-out to be completed Decrease peroxide initiator to minimum of 0.6% by weight or 0.8% by volume. Do not reduce promoter

content below 0.4% by weight.

Defect: Air entrapment/laminate voids

Description: Air pockets in cured laminate

Defect: Pre-release lines

Description: Pre-release lines are wavy areas typically formed where the surface of parts has released slightly from the mold


39/64

Trouble Shooting


E6


1. Inadequate mixing of peroxide initiator For external mix, use a tip that gives the proper degree of fan to allow for complete mixing.

For internal mix, use different static mixer or use extension with air assist

2. Low peroxide initiator and/or promoter concentration. This results Use only recommended type and concentration of promoters and peroxide initiators.

in under-cured or non-cured substrate laminates Ensure dispensing equipment is suitable and in proper operating condition.


1.High resin compound mix-to-glass ratio Lower resin l ine pressure or increase chopper speed on gun. Maintain 41% resin/41% filler/ 18% glass.

2 . L ow v is co si ty o r t hi xot ro pi c in de x M ai nt ain r es in t o fil le r r at io of 1 t o 1 . Us e o nly s pe cifi c fi ll er s r eco mm en de d.

3. High resin t emperat ure By cooling resin t o 70 80F (21. 1 26.7C), viscosity will be increased.

4 . L on g la min at e ge l t im e Us e o nl y r ec om men de d t ype a nd le ve ls o f pe ro xid e i ni tia to r a nd pr om ot er s ( if u sin g 33 540 ). R ec ali br at e

dispensing equipment. Review causes under Slow Cure and Spotting Cure pages E1-a & b.

5 . Fi ll er dr op -o ut i n r esi n Re cal cul at e fil le r c on te nt a nd if r eq uir ed a dju st t o 50 % b y weig ht . M ix d rum t o r e- dis pe rs e fil le r.

Use only recommended fillers.

Defect: Drainage

Description: The resin drains out of the laminate on vertical surfaces forming puddles on the bottom and dry glass on the top. (Excessively large puddles of resin may cause

heat lines and/or pre-release.)

Defect: Resin weeping

Description: Droplets of liquid resin penetrating through gelled laminate


40/64

Trouble Shooting


E7


1. Improper or inadequate preparation of master Use proper release agents. Reapply release agent to master. Apply a parting film (PVA).

Employ mold maintenance program.

Use extra layers of wax or parting film (PVA). Follow mold release agent

manufacturers recommendations.

2. Design of the master Eliminate reverse drafts or insufficient drafts in master.

3. Over spray or other foreign material on master before gel coat is applied Keep master protected when not in use. Clean and inspect prior to use.

4.Artificial vacuum between master and mold Break with compressed air. Design master with poppets in required areas.


1. Low exotherm Maintain minimum thickness of 120 mils (3.05 mm) for each cure cycle. Maintain minimum material

temperature of 85F. Maintain recommended peroxide initiator and promoter concentration. lnspect

equipment for restrictions.

2. Low peroxide level Maintain 1-2% Superox

46750 or 46709 peroxide based on resin used.

3. Poor peroxide mixing Check gun for proper mixing of peroxide initiator.

Defect: No laminate color change

Description: Laminate fails to turn white upon curing

Defect: Tool sticking on master

Description: Tools are difficult to remove from master after cure.


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Trouble Shooting


E8


1. Slow cure Review causes under Slow Cure and Spotty Cure. See pages E1-a, E4-a & b

2. Part demolded before properly cured Do not demold until part has achieved a minimum Barcol hardness of 45.

3. Insufficient gel coat cure or thickness Ensure proper application. See causes under Fiber print through above.


1 . L am in at e ex ot he rm i s t oo lo w M ai nt ain m in im um t hic kne ss o f 12 0 m il s (3.05 m m). f or e ac h c ur e cy cle . M ain ta in an d m at er ia ls a t

85F or higher. Based on resin content, increase Superox 46-750 (33540 or 33541) or Superox 46-709

(33542) peroxide initiator to 12%.

2. Gel coat not fully cured when laminate is applied Ensure gel coat application conforms to manufacturers recommendation. Switch to faster curing gelcoat. Allow more time for gel coat to cure. Increase plant and/or master temperature.

3. Long gel time allows styrene to soften gel coat Increase peroxide initiator concentration. Increase plant/materials temperature.

4. Gel coat is too thin Follow manufacturers recommendations.

5. Fiber print pattern in master Replace or refinish master.

6. Excessive shrinkage. Polylite Profile resin contaminated Discard resin.

with other polyester resins

Defect: Fiber print through

Description: Individual glass fibers can be seen through gel coat

Defect: Post cure

Description: The appearance of fiber or roving print through after the part has been demolded


42/64

Trouble Shooting


E9


1. Cracks Inspect resin and air line for contamination (such as oil).

2. Cracks of various lengths occur in close proximity to radius areas. Reduce first fiberreinforced resin layerto an approximate thickness of 2030 mils.

Commonly occurs after second or third forming cycle. Remove entrapped air before proceeding to the next laminate application. Laminate applications

must have a minimum thickness of 120 mils (305 mm) prior to gel and cure. Use 14 inch long chop in first 2030 mils of skin coat.

Reduce filler content to 45% by weight.

Run 6 blades in chopperalternate and inch glass in first 20-30 mils of skin coat. Chop one

strand of roving. Adjust chopper motor speed to maintain proper resin to glass ratio. Adjust resin to

glass fan to ensure uniform wet out and composition. Maintain resin compound temperature at

2932 (85 5F). Use brush to assist with wet out.

Roll laminate using brissel type or bubble buster roller. Inadequate mixing of additives during

application. Review mixing procedure described in tooling manual.

3. Droplets (blister often vinegar odor) Make sure the peroxide initiator flow stops when the trigger on the gun is released. Keep gun tip clear.

4 . Pe ro xid e In it ia tor. Ad ju st o r m od if y m ix ing ca pa bil it ie s o f e qui pm en t.V is ua ll y in spe ct la min at e t o e ns ur e u nif or m m ix in g

after initial catalyzation.

Defect: Blisters

Description: Blisters forming on the surface of the part. The blister may or may not contain a liquid.


43/64

Trouble Shooting


E10


1. Improper rol l-out or excessively thick Rol l out between each 20-40 mils (0.51 - 1.2 mm) application of chop.

Roll out using moderate speed and pressure.

2 . D ra in ag e f ro m l ow v is cos it y l ea ve s a ir v oid s Re vie w c au ses u nd er Dr ai na ge . Consult page E6.

3. High viscosity Retest filled viscosity. Recalculat e resin and filler addition. Maintain 1 t o 1 ratio by weight.

Reduce filler content to 45% minimum. Increase filled resin mix temperature to

7080F (21.126.7C). Do not add additional monomers. Only Polylite 33540 Series

may be added to restore proper filler-to-resin ratio.

4 . R es in -s ta rv ed a re as M ai nt ain p ro pe r r esi n m ix -t o- gla ss r at io . P re- wet p ar t wit h fi ll ed r esi n p rio r t o a pp lic at io n o f l am in at e.

5. Short gel time does not allow glass wet-out to be completed Decrease peroxide initiator to minimum of 0.6% by weight or 0.8% by volume.

Do not reduce promoter content below 0.4% by weight.

Defect: Air entrapment/laminate voids

Description: Air pockets in cured laminate


44/64

Trouble Shooting


E11


1 . P re u se m ic ro cr ac ki ng. E xce ss iv e f or ce Re des ign m as te r pl ug t o e ns ur e s uf fic ie nt .

2. Used during demolding tool from master Draft angles. Refinish and or apply release agents to master. Rigidize tool to prevent flexing.

Reduce air pressure used to assist demold.

Defect: Cracks

Description: Cracks of various lengths occur in close proximity to radius areas. Commonly occurs after second or third forming cycle.


1. Excessive gelcoat thickness Reduce cured gelcoat t hickness to . 007.012 ( 0. 180.305 mm) .

2. Inconsistent gelcoat thickness Use thickness gauge during application

3. Thermal shock. Tool exposed to wide temperature differentials Warm tool prior to production. Avoid exposing (storing/staging) hot tools to extreme cold.

4. Gelcoat t oo rigid Use tougher, higher elonga tion gelcoat. Consult wit h gelcoat manufacturer t o ensure proper select ion.

5. Incomplete cure of gelcoat Follow manufactures applications instruction.

6.Thermoforming cycle t ime too long. Reduce cycle t imes; balance vacuum throughout tool. Heat acryl ic sheet evenly.

Faster cool down of formed acrylic sheet.

7. Uneven thermal expansion of gelcoat. Reduce cycle t imes. Heat acryl ic sheet evenly to avoid hot spots.

Defect: Cracks

Description: Various lengths which may occur either in localized areas or throughout the tool.


45/64

Typical Polylite Profile Resin PropertiesNeat


F1

PROPERTIES UNITS TEST METHOD VALUES

Flash Point, Seta Closed Cup F (C) 89 (31.7)

Shelf Life, Minimum Months N/A 3

% Styrene Monomer 18-001 47.5

Weight/Gallon lb (kg) 18-030 8.8 (3.99)

Viscosity, Brookfield Model LVT, cps 18-021 120

#1 Spindle @ 30 RPM

Gel Time, 1.25% Superox Minutes 18-050 25

46750 Peroxide Initiator and

0.5 parts 46559 Polylite

promoter by weight

Time to Peak Minutes 18-050 33

Peak Temperature F (C) 18-050 415 (212.8)

Color, Liquid 18-043 Clear Amber

Neat resin tested at 77 F ( 25 C )


46/64

Typical Polylite Profile Resin Properties


F2

PROPERTIES UNITS TEST METHOD VALUES

Gel Time Cup Values minutes

Time to Peak minutes

Peak Temperature F (C)

Viscosity, Brookfield Model LVF cps 18-021 850

#3 Spindle @ 60 RPM

Weight/Gallon lbs (kg) 18-030 12.3 (5.58)

Linear Mold Shrink in/in (cm/cm) 0.0002 (0.0002)

Specific Gravity ASTM D792 1.48

Tensile Str. Yield lb/in2 (kg/cm2) ASTM D638 7,500 (527)

Flexural Str. Yield lb/in

2

(kg/cm

2

) ASTM D790 14,000 (984)

Elongation @ Break 1% ASTM D638 1.0

Tensile Modulus lb/in2 (kg/cm2) ASTM D638 15.3 x 105 (1.08 x 105)

Compressive Str lb/in2 (kg/cm2) ASTM D695 19,500 (1370)

lzod, Notched, R.T. ft lb/in (kg cm/cm) ASTM D256 29.9 (5.5)

Barcol Hardness 934-1 50

Linear Therm Expan in/in F (cm/cm C) ASTM D696 1.2 x 106 (2.16 x 106)

Resin reinforced with 20% chopped glass fibers and tested at 77 F ( 25 C )

See Promoter Levels Versus Gel Time and Temperature Chart on page C3


47/64

Typical Polylite Profile Resin Physical Properties


F3

The following table shows the physical test results using three

filler and glass combinations.

A B C

Tensile Strength, psi 8.58 x 103 1.10 x 104 1.47 x 104

Flexural Strength, psi 1.49 x 104 1.91 x 104 2.11 x 104

% Elongation 1.76 2.09 2.67

Tensile Modulus, psi 9.96 x 105 1.04 x 106 1.059 x 106

Flexural Modulus, psi 7.58 x 105 9.58 x 105 8.84 x 105

Izod IMpact Strength, Not ched 11.5 ft 1b/in 9.8 ft 1b/in 10.1 ft 1b/in

LAMINATE CONSTRUCTION

% Glass Content 20 26.7 26.5*

% ATH content 50 45 40

% Polylite Profile Tooling System 30 28.3 33.5

*Resin was not able to wet out more glass.

PHYSICAL PROPERTY EVALUATION


48/64

Technical Tips


G1

SYMPTOM REMEDY

Air Voids in Skin Coat. Reduce first fiberreinforced resin layerto an approximate thickness of 2030 mils. Remove

entrapped air before proceeding to the next laminate application. Laminate applications must have a

minimum thickness of 120 mils (3.05 MM) prior to gel and cure.

Use 14 inch long chop in first 2030 mils of skin coat.

Reduce filler content to 45% by weight. (For 33540 and 33541 series only).

Run 6 blades in chopperalternate 14 and 12 inch glass in first 2030 mils of skin coat.

Chop one strand of roving. Adjust chopper motor speed to maintain proper resin to glass ratio. Adjust

resin to glass fan to ensure uniform wet out and composition

Maintain resin compound temperature at 2932 (85 5F). Use brush to assist with wet out.

Roll laminate using brissel type or bubble buster roller.

Inadequate mixing of additives during application. Review mixing procedure described in tooling manual.

Air Voids in Pinch Area of Tool, 90 Corners or Small Deep Draw Areas Thoroughly wet out a sufficient quantity of glass roving with catalyzed r esin compound. Place in radii

area. Remove entrapped air. Do not allow to gel and cure before applying primary laminate.

Use filler paste. Consult page D5.


49/64

Technical Tips


G2

SYMPTOM REMEDY

Improved Sprayability Maintain resin compound temperature at 29 (85 5F)

Reduce filler content to 45% by weight. (For 33540 and 33541 Series only )

Convert pump pick-up tube from 34 inch to 1 inch diameter.

Remove fine mesh filters from pump pick-up tube and other in-line resin filters. Replace with 6080

mesh filters.

Adjust and clean application equipment. At end of each day flush equipment with non-filled Profile resin.

Leave pump piston on the down strokehelps to avoid possible buildup of filler on pump shaft.

L ong C om po un d Ge l Tim e Ve ri fy c onc en tr at io n a nd wei ght s of r es in , fil le r, p ro mo te r a nd pe ro xid e i ni tia to r. M ain ta in FI FO i nve nt or y.

Increase Reichhold 46559 promoter to a maximum level of 1.0% by weight. (For 33540 Series only).

Warm resin compound to 29 (85 5F).

Mix 46559 promoter into resin for a longer period of time: 510 minutes.

Confirm and use only approved fillers.

Use different lot of filler.


50/64

Technical Tips


G3-a

SYMPTOM REMEDY

Short Gel Time Resulting From Elevated Work Place Temperatures Reduce amount of Reichhold Promoter (33540) and or initiator (33540 and 33541).

Laminate Slippage Disperse filler using a Cowls mixing blade.

Adjust filler content to 45% by weight and add up to 0.25% by weight fumed silica.

Maintain a 10 mil or less mist coat of resin compound.

Confirm that only approved fillers are in use.

Inadequate Mixing of Initiator or Initiator Streaking Equipment not adjusted properly or in need of cleaning or repair. Take appropriate action.

Warm resin compound to 29C32C (85F90F).

Inspect turbulent mixer used in equipment. Replace with new or more efficient unit. In some equipment

a nylon unit performs better that teflon. Teflon soft enough that flutes can collapse, causing a loss of seal

to the chamber and initiator streaming or improper mixing.

Cured Laminate Has Green Colored Surface Over catalyzation. Repair or adjust dispensing equipment.

Review tooling manual for suggested concentration.

Wrong peroxide initiator used. Use only Superox 46750.


51/64

Technical Tips

33542 Series

G3-b

SYMPTOM REMEDY

Short Gel Time Resulting From Elevated Work Place Temperatures Reduce amount of initiator.

Laminate Slippage Disperse filler using a Cowls mixing blade.

Maintain a 10 mil or less mist coat of resin compound.

Confirm that only approved fillers are in use.

Inadequate Mixing of Initiator or Initiator Streaking Equipment not adjusted properly or in need of cleaning or repair. Take appropriate action.

Warm resin compound to 29C32C (85F90F).

Inspect turbulent mixer used in equipment. Replace with new or more efficient unit. In some equipment

a nylon unit performs better that teflon. Teflon soft enough that flutes can collapse, causing a loss of seal

to the chamber and initiator streaming or improper mixing.

Cured Laminate Has Green Colored Surface Over catalyzation. Repair or adjust dispensing equipment.

Review tooling manual for suggested concentration.



52/64

Technical Tips


G4-a

SYMPTOM REMEDY

Surface Distortion of completed Tool or Part Increase temperature of work place and master part.

Verify concentration and weights of resin, filler, promoter and peroxide initiator.

Inadequate mixing of additive materials. Review mixing procedures and adjust dispensing equipment.

Brush or roll mist coat of resin compound.

Over-catalyzation/under-catalyzation. Review manual and make necessary adjustments or equipment

repairs.

Warm resin compound to 2932C (8590). Maintain temperature during application. Increase work

place temperature.

Improper or inadequate gelcoat cure. Consult manufacturer.


Raise laminate exotherm by increasing cross sectional thickness of laminate prior to gel and cure.


53/64

Technical Tips

33542 Series

G4-b

SYMPTOM REMEDY

Surface Distortion of completed Tool or Part Increase temperature of work place and master part.

Verify concentration and weights of resin and peroxide initiator.

Inadequate mixing of additive materials. Review mixing procedures and adjust dispensing

equipment. Brush or roll mist coat of resin compound.

Over-catalyzation/under-catalyzation. Review manual and make necessary adjustments or

equipment repairs.

Warm resin compound to 2932C (8590). Maintain temperature during application.

Increase work place temperature.

Improper or inadequate gelcoat cure. Consult manufacturer.


Raise laminate exotherm by increasing cross sectional thickness of laminate prior to gel and cure.


54/64

Technical Tips


G5

SYMPTOM REMEDY

L ow La min at e M ech an ic al Pr op er tie s C or re ct a nd c on fir m t ha t p ro per in it ia tor a nd c on cen tr at ion a re u se d.

Increase temperature of work place and resin compound during application.

Reduce filler content to 45% by weight and increase content of glass reinforcement.

(For 33540 and 33541 Series only).

Incorporate uni-directional and/or bi-directional glass.

Increase length of chopped glass.

Increase thickness of final laminate.

Cracked Flange Area of Tool Reduce air in skin coat.

Hand lay uni-directional and/or bi-directional glass.

Increase cross sectional thickness of flange with composite.

Reduce filler content to 45% by weight and increase content of glass reinforcement.

Increase length of chopped glass.


55/64

Technical Tips


G6

SYMPTOM REMEDY

StickingTool to Master, or Part to Tool Misapplication of materials used to construct masterfollow manufacturers recommendation.

Use PVA parting film.

Design the master or part with proper draft angles.

Inadequate gelcoat cure. Follow manufactures recommendation.

(This can also appear as hazing of gelcoat.)

Gelcoat porosityreview and correct application techniques.

Improper or inadequate use of release agents. Follow manufacturers application recommendations.

R ep air s Se co nd ar y B on d Th or oug hly a br ad e wit h 60 g rit s and p ap er a nd cle an. Wa rm Po lyl it e Pr ofi le Se ri es r es in c om po und t o

2932 C (8590 F). Use chopped and bi- or uni-directional glass. Use step shingle laminate

extending at minimum of 6 inches from edge of repair.

Prepare surface with Atprimefollow directions for use.

Poor, or Lack of, Adhesion to PVC Core Material PVC core materials have not been evaluated for use with Polylite Profile and are therefore notrecommended at this time.


56/64

Technical Tips


G7

The following table will assist the Polylite Profile user to estimate the amount of material required for a given thickness of composite. Values are based on pounds per square foot of

composite which incorporate a 1:1 ratio resin to filler and 19% by weight chopped continuous strand roving. The term composite refers to resin, filler and chopped strand roving content only.

Thickness (mils) 1.000 .8750 .7500 .6250 .5000 .3750 .2500 .1250

Thickness (inches) 1 78 34 58 12 38 14 18

Composite, weight 8.15 7./13 6.11 5.10 4.08 3.06 2.04 1.02

Resin, weight, (lbs) 3.30 2.88 2.48 2.04 1.64 1.23 0.82 0.41

Filler, weight, (lbs) 3.30 2.88 2.48 2.04 1.64 1.23 0.82 0.41

Glass, weight, (lbs) 1.55 1.37 1.15 1.02 0.80 0.60 0.40 0.20

Note: Add approximately 10% for waste


57/64

Technical Tips


G8

STEP 1

Prior to fabrication, read, view and understand Reichholds tooling manual and video. Read and understand all product literature and material safety data sheets.

STEP TWOMASTER PLUG

A. Construct master plug and finish to exact dimensions and surface smoothness.


STEP 3

A. Review the Resin Compounding and Pre-Application Quality Control sections, pages B1-D4.

Thermoformed Acrylic Tool Fabrication

This guide is intended to assist the fabricator with construction of Polylite Profile tools which will be used to thermoform either cast or extruded acrylic sheet. Only tools fabricated by

glass reinforced spray-up techniques will be reviewed. The guide was compiled from information provided by fabricators and material suppliers. This information represents current

state-of-the-art at the time of printing and is intended for guidance purposes. Final design, application and material selection is the sole responsibility of the fabricator. Because

construction materials differ among composition, application and performance, and due to a variety of thermoforming process conditions, we recommend each user thoroughly

evaluate this tooling system for suitability.


58/64

Technical Tips


G9

STEP 4GEL COAT

A. Spray on two or three passes of a suitable gel coat to develop a 712 mu (0.20.3 mm) thickness. Thickness of over 12 mu (0.3mm) may result in cracking. Spraying gel coat

to a uniform thickness onto small irregular molds can be difficult. A combination of low spray pressure and small diameter spray tips is suggested. Allow to cure to a tacky feel.

An external heat source may be required to ensure that proper degree of cure is achieved.

B. The use of tough heat resistant gel coats are suggested. These include vinyl ester (aluminum and non-aluminum filled) and isophthalic/neopentyl glycol based products.

C. Follow all gel coat manufacturers recommendations for handling and applications.

NOTE: The fabricator may elect not to employ a gel coat. It may be advantageous to eliminate the gel coat when fabricating small irregular shaped molds or molds that are subjected

to temperatures over 176C (350F). If a gel coat is not used, a one to two ply 1.5 oz. per square foot Hydrex Series laminate may be used.

STEP 5NON FILLED PRIMARY LAMINATE (OPTIONAL)

A. To minimize the potential of air entrapment within the primary laminate, a non-filled laminate may be a pplied after the gel coat step. This laminate should be applied to a

thickness of 17.535 mils (0.440.89 mm) using Hydrex 33390 vinyl ester hybrid or Polylite 33346 vinyl ester resin. A resin to glass ratio of 7075:3025 should be

maintained. The primary laminate should be permitted to cure 24 hours prior to laminating with the Polylite Profile system. Read and understand both the product bulletin and

material safety data sheet prior to using Hydrex 33390.

STEP 6LAMINATE APPLICATION

A. Spray a mist coat of resin compound to an appropriate thickness of 10 mils (0.25 mm). This should completely wet the surface. Only mist an area which can be

worked prior to gelation.

B. A brush may be used to assist with coverage and removal of entrapped air.

C. Apply a fiber-reinforced Polylite Profile Tooling resin layer to approximate thickness of 3045 mils (0.761.14mm) accomplished in one or two passes.


59/64

Technical Tips


G10

STEP 7ROLLOUT

A. Remove all entrapped air with a brush or roller after each pass. Carefully inspect and remove air voids in laminate before proceeding to the next laminate application.

Laminate applications must have a minimum thickness of 120 mils (3.05 mm) prior to gel and cure.

B. Work out all entrapped air.

STEP 8CURE

A. Allow the exotherm of each 120 mils (3.05 mm) laminate to subside before proceeding with subsequent applications. Failure to do so will decrease the working t ime of

subsequent laminations. Because in-service requirements of tools vary, it may be necessary to apply multiple laminates to achieve the desired cross sectional thickness of the

completed tool.

B. Repeat Step 7, as needed, to achieve the required composite thickness.

C. After each laminate application, trim excess glass from flange edge of the tool after partial cure is reached. The use of backup core reinforcements is not recommended.

STEP 9VACUUM CHANNELS

A. Construct all vacuum chanels from suitable materials.

B. Laminate vacuum chanels to designated locations throughout tool. After completion of cure pressure test using 35 psi of compressed air, repair as required.

STEP 10ADD BACKUP REINFORCEMENT STRUCTURE

A. Cut and tailor a backup structure as required to maintain proper equipment.

B. Scuff sand attachment points on the tool as required to ensure a proper fit.

C. Position structure on the tool and attach by spraying chop around each attachment point.


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Casting


H1

PROCEDURE FOR MASS CASTING WITH ALUMINUM POWDER AND SHOT

1. Gel coat mold or plug with aluminum filled gel coat. Allow gel coat to cure to a very light tack.

2. Use a mixer like the type used to make cultured marble or concrete. Do not use blade type mixer used for tooling resins.

Those mixers will not handle the high viscosity.

3. Add resin to mixer.

4. Add 0.4% 46559 promoter (if using 33540) to resins and mix 2 minutes or until completely mixed.

5. Add 0.75-1% 46750 peroxide initiator. Mix for 2 minutes or until completely mixed.

6. With mixer running, add aluminum shot. Weight of shot should be two times the w eight of the resin used.

Mix until shot is completely wet-out by resin.

7. With mixer running, add aluminum powder.Weight of powder should be two times the weight of the resin.

Mix until powder is wet-out by resin.

8. Slowly add additional powder until no free resin is observed in the mix. Mix should have the consistency of a marble or concrete mix.

Mix needs to be thick enough to prevent settling of the shot.

Typical ratios are as follows:

Resin 16-18%

Aluminum Shot 38-40%

Aluminum Powder 42-44%

9. Allow casting to cool down completely before removing from plug or mold


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Casting


H2

PROCEDURE TIME

1. Casting forms constructed and master secured, waxed and PVA applied 2 hours

2. Gelcoat applied/cure 2 hours

3. Surfaces brush coated with Profile (20%)/Aluminum powder (80%) mixture. 0.25 hours

Reichhold 46559 promoter 0.5% by weight. Superox 46750 1.5% by weight..

Gel time 5 minutes.

4. Cavity and flat back section pours were made prior to curing item 3 above.

Each pour consisted of the mixture as outlined above.

a) Polylite 46559 promoter mixed into 33540 0.1 hours

b) Superox 46750 ini tiator mixed into 33540 and 33541 0.1 hours

c) Aluminum powder added to mix immediately followed by sphery shot 0.2 hours

5. Geltime

Cavity section 0.3 hours

Flat back section 0.3 hours

6. Cavity section allowed to cure 24 hours prior to pouring of flat back section

7. Drill and secure alignment bolts 0.15 hours

PHYSICAL PROPERTIES POLYLITE PROFILE CAST TOOLING

Compressive strength:

Materials

Polylite Profile Tooling resin 100

Polyl ite 46559 series promoter (for 33540) 0.3

Aluminum powder 315

Aluminum pellets 350

Superox 46750 catalyst (for 33540 and 33541) 1.0

Compressive strength @ 77F, psi. 9,465

Compressive modulus, psi. x 105 2.53

Compressive strength @ 150F. psi. 4,438


Compressive strength @ 300F, psi. 2577


Co ef fic ie nt o f Th er ma l E xp ans ion , x 10 6/F 1 9

(-59300F)

Th er ma l Co ndu ct iv it y (K) W /m * K 3.36 @ 16 5 F

Heat Capacity (Cp), J/kg*K 1 050

Specific gravity gm/cc 2.18


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Packaging / Safety / Quality / Storage


I1

Packaging

Non-returnable 55-gallon metal drums or 42,00044,000 lbs tank truck

MaterIal Safety Data

Read and understand the MATERIAL SAFETY DATA SHEET before using this product.

Material Safety Data Sheets are available from your Reichhold representative. Make certain you

obtain a copy of the Material Safety Data Sheet on this product. Users should request and

understand such information from the suppliers of all materials prior to working with thesematerials.

Reichhold Quality Policy

Reichhold is committed to quality performance. We will satisfy the needs of the

marketplace with innovative products which maximize value and performance, delivered

to specification and on time.

Storage

To ensure maximum stability and maintain optimum resin properties, Dion, Hydrex

and Polylite, resins should be stored in closed containers maintained below 75F (23.9C) and

away from heat sources and sunlight. All storage should conform to local fire and building

codes. Drum stock should be stored away from all sources of flame or combustion. Inventory

levels should be kept to a reasonable minimum with first-in, first-out stock rotation.

Additional information on handling and storing unsaturated polyesters is available in Reichholds

Application Bulletin, General Information of Storage and Handling Unsaturat ed Polyester Resins.

For product information on other Reichhold resins, or Superox peroxide initiators, please

contact your sales representative or your nearest Reichhold distributor.

Disclaimer

The recommendations made herein are based on our research and experience and that of

others and are believed to be accurate. No guarantee is made to the accuracy or the results

to be obtained from using any of the recommendations. Each manufacturer should make their

own determination on the suitability of any recommendation for their own particular application

and system. Nothing herein shall constitute or be construed as an express or implied warranty

of any recommendation and the manufacturer assumes all risk associated with using any of

the recommendations.


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Polylite Profile Distributors


I2

AlabamaComposites OneMobile888-221-8133

Ashland DistributionMobile800-531-7106

Advanced PlasticsElberta

800-327-6136

ArkansasComposites OneVan Buren800-457-7017

ArizonaComposites OnePhoenix800-522-2599

Ashland DistributionChandler

888-877-0963

CaliforniaComposites OneW. Sacramento800-654-5223

Composites OneMadera888-588-8520

Composites OneSanta Fe Springs800-237-0087

Ashland DistributionCarson888-877-0963

Ashland DistributionFairfield888-877-0963

ColoradoGeorge C. BrandtCentennial

303-584-0717

FloridaComposites OneLakeland800-344-0656

Composites OneMiami800-432-2752

Ashland DistributionMiami800-531-7106

Ashland DistributionTampa800-531-7106

Fiberglass CoatingsSt. Petersburg727-327-8117

GeorgiaComposites OneValdosta800-458-5916

Composites OneLawrenceville800-423-7874

Ashland DistributionDoraville

800-531-7106

HawaiiFiberglass HawaiiHonolulu808-847-3951

IllinoisComposites OneWoodstock800-435-6138

Ashland DistributionWillow Springs

800-531-7106

IndianaComposites OneGoshen800-348-7503

Ashland DistributionElkhart800-531-7106

KansasAshland DistributionKansas City

800-531-7106

LouisianaAshland DistributionBaton Rouge800-531-7106

Advanced PlasticsHarahan504-738-6035

MaineComposites One

Rockland207-594-7503

MassachusettsAshland DistributionTewksbury800-531-7106

MichiganAshland DistributionWarren800-531-7106

Minnesota

Composites OneLino Lakes800-457-7011

Ashland DistributionShakopee800-531-7106

MissouriComposites OneNorth Kansas City800-457-7975

Ashland DistributionSt. Louis800-531-7106

New JerseyComposites One

Millville888-722-3371

North CarolinaComposites OneSmithfield919-209-0840

OhioComposites OneAshtabula800-553-5483

Composites One

Dayton800-334-7498

Ashland DistributionTwinsburg800-531-7106

OklahomaAshland DistributionTulsa800-531-7106

OregonAshland Distribution

Portland888-877-0963

PennsylvaniaComposites OneMonessen800-736-0999

Ashland DistributionMorrisville800-531-7106

Rhode IslandComposites One

Bristol800-343-3030

TennesseeComposites OneLa Vergne888-457-3401

Ashland DistributionKnoxville800-531-7106

Advanced PlasticsNashville

800-321-0365

TexasComposites OneFort Worth800-752-7839

Composites OneHouston800-451-8459

Ashland DistributionGarland800-531-7106

Ashland DistributionHouston800-531-7106

Johnson FiberglassSouth Houston713-946-8444

UtahComposites OneSalt Lake City

800-444-0156

Ashland DistributionClearfield888-877-0963

VirginiaAshland DistributionRoanoke800-531-7106

WashingtonComposites OneVancouver

800-255-6006

Composites OneArlington800-283-0809

WisconsinComposites OneDe Pere920-336-5898

Ashland DistributionMenasha800-531-7106


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To receive information on the Polylite Profile Tooling System, Hydrex high-performance resins or other Reichhold products, call your local Reichhold representative.

Relchhold World Headquarters and Technology Center

PO Box 13582

Research Triangle Park, NC 27709-3582

800.448.3482 (General Information)

800.431.1920 ext. 1 (Product Inquiries)

www.Reichhold.com

Corporate Headquarters

Documents

Tooling Manual - Reichhold