Nord Composites S.A.

Norester RM 2000/50 is a specially formulated, unsaturated polyester resin designed to produce long life, high quality moulds for the fabrication of thermosetting composite parts.
The single component, pre-accelerated, filled resin will cure at room temperature to produce a zero shrink mould without fiber print through. With the rapid cure and ease of handling of RM 2000/50, moulds can easily be produced in a single day.

APPLICATIN RECOMMENDATIONS
 Workshop Conditions
In order to achieve the necessary level of cure with Norester? RM 2000/50, the workshop must have a minimum temperature of 15oC, ideally 18-25oC. Above 25oC, we recommend the LGT version.
If the temperature is too low the optimum cure and zero shrink properties will not be achieved.

1 Preparation The surface of the plug must be free from voids and defects, with a propriety release agent applied.

2 GEL COAT Nord isophthalic tooling gel coat GC 200/201 is recommended for optimum tool life. For enhance durability GC 206/207, vinyl ester gel coat should be used.
Both are available to spray or brush and can be supplied in black, blue and green. Gel coat thickness should be between 600 and 800 microns. The gel coat must be fully cured before any reinforcing layers are added.

3 Norester® RM 2000/50 Application & Catalyst
Before use, mix the resin well, to achieve a homogeneous product.
Catalyst MEKPO must be used to catalyst Norester® RM 2000/50. Typically 1 to 1.25% should be used for optimum cure. Using more than 1.25% or less than 1% Calyst MEKPO will result in poor cure and laminate properties.

First Layer
In any laminate it is important that the first reinforcing layers are fully consolidated with all the air removed. Depending on the required performance of the finished mould the first layer can be :

1 x 200 or 300 gr/m2 chopped strand mat (emulsion bound) with the resin Norester® RM 2000/50
• A surface tissue or 1 x 200 or 300 gr/m2 chopped strand mat (powder or emulsion) with resin ISO-NPG Norester® 568
• A surface tissue or 1 x 200 or 300 gr/m2 chopped strand mat (powder or emulsion) with vinylester resin Norester® 680
When using a first layer with Norester® 568 or Norester® 680, these should be fully cured before backing up with Norester® RM 2000

4 Norester® RM 2000/50 Laminate
The Norester® RM 2000/50 is a low viscosity, easily consolidated resin which operates at a 4:1 resin glass ratio. After the first reinforcing layer has been put down 3-4 layers of 450 gm/m2 chopped strand mat can be laminated, or 1,300 – 1,800 gm/m2 of resin and glass sprayed down. The maximum amount of glass fiber which can be put down and easily handled before curing is 2,100 gm/m2

After the first laminate is cured and has cooled a further 1,800 – 2,100 gm/m2 can be laid down to build mould thickness if required.

5 Curing Norester® RM 2000/50
The Norester® RM 2000/50 is a fast curing resin system with a sharp gel point. When the laminate starts to cure a temperature rise to 50-60oC will be noticed and the colour will change from a mid brown to a lighter white/brown colour.
When cure is complete and the laminate has cooled, a second layer can be applied and so on.

6 Mould Stiffening & Reinforcing Elements
Stiffening and reinforcing ribs can be added to the back of the mould as with any composite mould. These can be laminated in as soon as the mould is fully cured and has returned to room temperature. This will not cause any deformation to the mould surface. It is not, therefore, necessary to wait 2-3 days for the mould to post cure.

 From Plug to Mould Workshop Conditions

Down load picture 15 Step Manufacturing Sequence formulator of resins - gel coats - bonding pastes - pigment pastes
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This is document with 15 steps, details the manufacturing sequence for a composite mould, from basic plug manufacture to the final de- moulded product.

1a CNC ( Computer Numetic Control) machining of the Polyurethane foam. Machine the foam to between -8 to -12 mm of the final foam.

1b CNC ( Computer Numetic Control) machining of the Polystyrene foam. Machine the foam to between -8 to -12 mm of the final foam.

2 Application of the resin Norester 854 to the Polystyrene plug. Apply 0.8 - 1 mm of resin to the polyestyrene ( density > 25 kg/m2) with a brush or roller. Laminate 2 layers powder bound mat, 300 g/m2 with the resin, roll between layers and make the laminate 10-15 cm wider than the plug dimention. Allow to care at ambient temperature for 24 hrs before applying the NCL 804PVR Gray.

3 Application of NCL 804PVRB Gray on the plug. Spray with spray gel coat machine (pump ratio 20 : 1), use sveral thin passes to obtain a thickness of 5-6 mm. To obtain the final dimension for machining it is necessary to :

A - 8 mm CNC machining : 2 layers.B - 12 mm CNC nachining : 3 layers

4 CNC machining of the NCL 804PVRB Gray

5 Application of Nord Appret 230. Apply 450 - 600 micron in several fine passes

6 Sanding of Nord Appret 230. Sand with a dry paper.

7 Application of Nord Laque 210. Spray with several fine layers in order to obtain the best finish.

8 Sanding the laque. Sand with different grades of wet & dry paper. Polishing the Laque with a polishing machine and different grades of polishing paste, until an utra high gloss shine is porduced

9 Application of release agent

10a Application of spray gel coat GC 207. Apply 700 to 800 microm layers, wet on wet in 4 or 5 passes.

10b Application of brush gel coat GC 206. Apply 700 to 800 micron layers in 2 passes.

11 Application of resin Norester 680 Apply 1 x 100 g/m2 powder bound mat 2 x 225 g/m2 powder bound mat.

12 Appliation of tooling resin RM 2000/50. Apply by hand lay up or spray gun using 2 rovings.

13 Rolling

14 Adding wooden reinforceing ribs

15 Demoulding