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Fiberglass molds are made from composites tooling materials and are used to make multiple copies of a part which may have a complex shape. They do wear down over time from use, but can last for many years and can be used to make hundereds of parts.
DAK Plastics is not in the mold making business, but we do work closely with very experienced composites tooling shops for when new molds are needed or existing molds need re-designed. We store all molds within our warehouses to keep them protected. We keep them clean and waxed to get the most possible use from them. Molds can be made for both the open and closed mold processes.
A very common form of fiberglass manufacturing is by open mold, spray gun applications. Hand held spray guns are used to apply composites resin and gel coat materials to the open mold. Gel coat is applied first, then a resin, catalyst and glass mixture. Materials such as mat, foam, wood or metal are hand-layed into the mold. Hand held rollers are used to remove air from the wet part. Once cured, the part is pulled, trimmed, and final finished.
The customer determines the specifications of the part. This includes the type(s) of composites materials to be used and the thickness of the applications. DAK Plastics uses TFM Machines and trains all sprayers in Controlled Spray Application. TFM Machines are very important to the process since they monitor the amount in pounds and ounces of resin and glass material applied. Controlled Spray Application is an applied work practice, to teach each sprayer hands-on to apply materials onto the mold as needed, instead of completely around it. The machines and work practice are methods to assure consistency of finished parts.
The open mold process generates hazardous air pollutants and other emissions that the EPA and State regulate. This process generates waste through overspray and the need to have spray booths to apply the materials. DAK Plastics maintains its compliance with these regulatory agencies and we continuously work to improve our methods of administration.
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