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VIDEO TUTORIAL

USED IN THIS PROJECT

Although not necessarily an exhaustive list, the following tools and materials, supplied by Easy Composites, were used in this project.

The quantity shown below is the approximate amount used in the project rounded up to the nearest available kit size or quantity.

TOOLS & EQUIPMENT
OV301 Precision Composites Curing Oven Thumbnail
OV301OV301 Precision Composites Curing Oven£1914.00 /each

Composites Laminating Brush 2" (50mm) Carton of 10 Thumbnail
BR-LAM-2-10Composites Laminating Brush 2" (50mm) Carton of 10£8.80 /pack

10kg High Capacity Digital Scales Thumbnail
SCALE10KG10kg High Capacity Digital Scales£13.96 /each

Total £0.00
MATERIALS & CONSUMABLES
Nitrile Gloves Thumbnail
NG[P]Nitrile Gloves* /each

Easy-Lease Chemical Release Agent 500ml Thumbnail
ELRA-05Easy-Lease Chemical Release Agent 500ml£19.80 /pack

Medium Mixing Cup / Catch-Pot Liner Thumbnail
CPLINERSMedium Mixing Cup / Catch-Pot Liner£0.24 /each

Long Mixing Sticks Pack of 25 Thumbnail
MIXL25Long Mixing Sticks Pack of 25£2.16 /pack

Soft Filleting and Filling Wax 330g Thumbnail
FILLWAX-330Soft Filleting and Filling Wax 330g£7.40 /block

Fluted Signboard 4-Pack 1220 x 610mm Thumbnail
FSBB-07Fluted Signboard 4-Pack 1220 x 610mm£17.10 /pack

EMP160 High Temp Epoxy Moulding Paste 5kg Kit Thumbnail
EMP160-5EMP160 High Temp Epoxy Moulding Paste 5kg Kit£102.60 /kit

EG160 High Temp Epoxy Tooling Gelcoat 5kg Kit Thumbnail
EP-G160-5EG160 High Temp Epoxy Tooling Gelcoat 5kg Kit£155.40 /kit

Total £0.00

VIDEO TUTORIAL

Hand Laminating a High Temperature Epoxy Mould

In this video we demonstrate how to hand laminate a mould using our EG160 High Temperature Epoxy Tooling Gelcoat and our EMP160 High Temperature Epoxy Mould Making Paste. The resultant mould can be used for out-of-autoclave (OOA) Pre-preg use as well as other applications where high temperature tooling may be needed.

For this tutorial, we are making a mould of some bonnet vents so we can eventually make carbon fibre versions of the vents using an OOA pre-preg. The pattern was pre-prepared using the original vents, our Fluted Signboard to make the Baseboard/flanges and the Soft Filleting and Filling Wax to fill the gaps in the vent and edges. Several applications of Easy-Lease Chemical Release Agent were applied before the pattern was then ready for the mould making process.

We then applied the EG160 High Temp Epoxy Tooling Gelcoat in two separate coats. A thin third coat is used as a coupling coat between the gelcoat and moulding paste. The EMP160 Epoxy Moulding Paste was then mixed and applied before the mould was left to fully cure. Once fully cured, the moulds were then removed from the pattern and given an oven post-cure before final trimming before being put into service.


TUTORIAL BREAKDOWN

Prepare the pattern

1. Prepare the pattern

We have taken the original vent and mounted it to some polypropylene Fluted Signboard to use as a base plate and flanges. All the gaps around the edge and the vent voids in the middle were filled and smoothed out using Filleting wax. The Pattern was then prepared with EasyLease Chemical Release Agent ready for the moulding process to begin.

Apply the first layer of EG160 tooling gelcoat

2. Apply the first layer of EG160 tooling gelcoat

Mixing up the first layer of Epoxy Tooling Gelcoat, it is brush applied evenly to the part and some of the baseboard to make the flanges. Take care to ensure an even layer is applied approximately 0.5mm thick.

The gelcoat is then allowed to part cure until what is known as the B stage. This is when, with a gloved finger, you can press on the gel lightly and it only leaves a slight mark on the gel but no gel residue on the glove. At this point we are ready for the second coat of gelcoat.

Apply the second layer of EG160 tooling gelcoat

3. Apply the second layer of EG160 tooling gelcoat

At this stage we can apply the second coat of gelcoat which is mixed up and applied the same as the first, aiming for an even layer around 0.5mm thick. Like the first layer, this coat is left until it is at the B stage of curing.

Apply a thin application of EG160 to act as a coupling coat

4. Apply a thin application of EG160 to act as a coupling coat

Next we mix up a small batch of the gelcoat and brush it in a very thin layer all over the surface. This is to act as a coupling coat between the gelcoat and the moulding paste. The gel is not left to cure this time as we are going to move over to applying the paste directly onto the wet gelcoat layer.

Apply EMP160 epoxy laminating paste

5. Apply EMP160 epoxy laminating paste

The moulding paste forms the main reinforcement for the mould itself. The paste is measured out and then a well is formed in the middle. The hardener is poured into this well. The paste is then kneaded, folded and thoroughly mixed to blend in the hardener until we are left with a even consistency paste.

The paste is then applied to the mould, initially filling in the inner part of the mould in the fine detail and corners. This is to ensure there are no voids or gaps between the gelcoat and paste. The paste is applied all over the whole surface and smoothed and patted down until a smooth even coating has been applied.

All the mould to fully cure at room temperature

6. All the mould to fully cure at room temperature

At this stage, the mould is left to fully cure and harden for a minimum of 24 hours at room temperature. Once fully cured, the mould is carefully removed from the base board and the pattern and filleting wax removed from the mould surface. The mould is cleaned and inspected ready to move on to the post cure.

Post-cure at high temperature

7. Post-cure at high temperature

Now that the mould has been cured and demoulded from the pattern, we need to conduct a post cure. This is done to develop the high temperature properties in the mould necessary to enable its use with out of autoclave pre-preg. This is done by returning the moulds to the oven for the post cure cycle.

A stepped postcure, as per the TDS, is used to allow the mould to develop its temperature resistance gradually without any risk of the mould distorting or softening during the process. Once the postcure cycle has achieved its final step, the moulds are then allowed to cool to room temperature. After some final tidying and trimming of the mould edges, they are now ready to be used to create some stunning pre-preg parts.


DISCUSSION (0)

Please share any questions or comments you may have about this video tutorial.

LEAVE A COMMENT OR QUESTION

Note: Your name will be abbreviated and your email address will only be used to email you the answer directly

USED IN THIS PROJECT

Although not necessarily an exhaustive list, the following tools and materials, supplied by Easy Composites, were used in this project.

The quantity shown below is the approximate amount used in the project rounded up to the nearest available kit size or quantity.

TOOLS & EQUIPMENT
OV301 Precision Composites Curing Oven Thumbnail
OV301OV301 Precision Composites Curing Oven£1914.00 /each

Composites Laminating Brush 2" (50mm) Carton of 10 Thumbnail
BR-LAM-2-10Composites Laminating Brush 2" (50mm) Carton of 10£8.80 /pack

10kg High Capacity Digital Scales Thumbnail
SCALE10KG10kg High Capacity Digital Scales£13.96 /each

Total £0.00
MATERIALS & CONSUMABLES
Nitrile Gloves Thumbnail
NG[P]Nitrile Gloves* /each

Easy-Lease Chemical Release Agent 500ml Thumbnail
ELRA-05Easy-Lease Chemical Release Agent 500ml£19.80 /pack

Medium Mixing Cup / Catch-Pot Liner Thumbnail
CPLINERSMedium Mixing Cup / Catch-Pot Liner£0.24 /each

Long Mixing Sticks Pack of 25 Thumbnail
MIXL25Long Mixing Sticks Pack of 25£2.16 /pack

Soft Filleting and Filling Wax 330g Thumbnail
FILLWAX-330Soft Filleting and Filling Wax 330g£7.40 /block

Fluted Signboard 4-Pack 1220 x 610mm Thumbnail
FSBB-07Fluted Signboard 4-Pack 1220 x 610mm£17.10 /pack

EMP160 High Temp Epoxy Moulding Paste 5kg Kit Thumbnail
EMP160-5EMP160 High Temp Epoxy Moulding Paste 5kg Kit£102.60 /kit

EG160 High Temp Epoxy Tooling Gelcoat 5kg Kit Thumbnail
EP-G160-5EG160 High Temp Epoxy Tooling Gelcoat 5kg Kit£155.40 /kit

Total £0.00

DISCUSSION (0)

Please share any questions or comments you may have about this video tutorial.

LEAVE A COMMENT OR QUESTION

Note: Your name will be abbreviated and your email address will only be used to email you the answer directly

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