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Fiberglass molds are made from composites tooling materials and are used to make multiple copies of a part which may or may not have a complex design. Over time fiberglass molds do wear down from use, but they can last for many years and can be used to make hundereds of parts.
DAK Plastics is very experienced in composite tooling for when new molds are needed or existing molds need re-designed. We store all molds inside our warehouse facilities to keep them protected, and clean and wax them regularly to get the most possible use from them. Molds can be made for both open and closed-molding processes.
A newer, and increasingly more popular form of fiberglass manufacturing is the closed-molding process that includes Light Resin Transfer Method (LRTM) and Bagging. Both have additional manufacturing benefits:
The LRTM requires two molds for each part. A hand held spray gun is used to apply the gel coat material to both molds. Materials such as mat, foam, wood or metal may be hand-layed into the molds. The two molds are then closed together and sealed so that catalysed resin material is then be transfered into them. This process allows for product requiring both sides be manufactured with an a-class finish.
Bagging requires a silicone bag be made and used as a form for the finished product. A hand held spray gun is used to apply the gel coat material to the mold. The bag is set and materials such as mat, foam, wood or metal may be hand-layed. The bag is sealed and catalysed resin material is then transfered. This process allows for the production of more complex parts, such as those with sharper radiuses or more curvatures.
With both processes, the product cures, is pulled, and is taken to final finishing.
Specifications are determined by you our customer. This includes the type(s) of composites materials to be used and the product thickness. TFM Machines monitor the amount of resin material injected as strokes; Controlled Spray Applications is an applied work practice to train all gel coat sprayers efficient material application methods. In the closed-molding process, additional psi of air pressure and strokes of material settings are established and used to assure consistency of your finished products.
The closed-molding process does not generate hazardous air pollutants or other emissions, other than during the initial gel coat application. This process eliminates the need for rolling, in most cases trimming, and the use of spray guns and spray booths for resin, catalyst and gun roving application. It creates an overall cleaner and less labor intensive facility when compared to the open-molding process, which is one major benefit for everyone.
DAK Plastics began offering the closed molding process in 2006 as an additional option for our customers. We continuously work to improve our methods of efficiency.
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