Energetx Composites manufacturing capabilities include hand lay-up. The process includes
- Coating a mold with a release agent, typically wax, and adding a layer of gelcoat to create the surface skin.
- Glass mats or fabric reinforcement are layered in the mold and impregnated with resin by brush or roller.
- Containing a catalyst and accelerator, the resin can cure at room temperature or be activated by moderate heat.
Advantages
- Simple processing
- Allows for all shapes and sizes
- Gel-goat provides good surface finish
- Cores can be molded in
- Investment is low, so low production numbers are possible
Disadvantages
- Low output creates high labor costs
- Structure properties vary with operator
- Working conditions include styrene emissions, which requires ventilation
Processing Thermoset Composites
Mold construction consists of contact-molded glass/polymer or glass/epoxy composite and a wooden or plaster plug. The molds are reusable and repairable. Simple shapes require just a one-piece mold, but complex or large shapes utilize several molds. The structure is created by bonding molded parts together. Air vents in the mold facilitate demolding, though there is often enough shrinkage to allow direct release.
Specific Aspects of Processing
- The molding surface
- The male mold creates the inner surface finish, the female mold creates the outer surface finish
- Both surfaces are coated with a mold release agent
- Structure has one smooth side facing the mold, and one rough side facing the operator
- The gelcoat
- The gelcoat is created from a layer of pure resin laid down on the mold surface
- It insulates from environmental conditions, particularly moisture penetration
- Guarantees good chemical strength
- Prevents unwanted deposits
- Carries pigments that color the finished product
- Protects against ultraviolet radiation
- The preferred application method is with a spray gun
- Reinforcing mats or fabrics
- It is cut into the proper shape for the part
- It is impregnated manually
- Reinforcements are placed over or in the mold, and the operator uses brushes or rollers to impregnate them with resin
- Star and washer rollers are used to facilitate air release
- Several layers can be laid up successively
- A thick structure cannot be created in a single step through this method