From Plug to Mould Workshop Conditions
Down load picture 15 Step Manufacturing Sequence formulator of resins - gel coats - bonding pastes - pigment pastes *** ***
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
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