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ME-542 Manufacturing with Non-metallic MaterialsHand-layup using fiberglass and polyester resin
Preparation:
Needed: Resin, catalyst, mold release, tooling, mixing cup, mixing stick, weighing device, eye dropper, gloves, drop cloth, paper towels, roller or plastic blade, scissors.
Obtain layup tooling surface that is smooth, hard and non-porous. The supplied cookie sheets are a good example.
Wear gloves. Supply ventilation to remove fumes.
Apply several coats of liquid release agent to the tooling; use a drying period of 5 minutes between each coat.
Rub the liquid mold release vigorously onto the surface until the surface is completely covered.
Cut desired layers of reinforcing material to the size required
Read the directions on the resin container carefully. Both resin and catalyst are harmful to the human body. Read MSDS sheets.
Molding:
Make sure all prep items are completed before mixing material.
Weigh the desired number of ounces of liquid resin into a mixing cup. Because the resin specific gravity is around 1.1, nine weight ounces is approximately eight fluid ounces.
Use the eye dropper to add 7 drops of catalyst per liquid ounce of resin to the mixing cup.
Immediately stir the mixed resin and catalyst with a disposable stick. Avoid stirring in bubbles, but stir long enough to insure even mixing. Roughly 30 minutes remains to finish the molding operation.
Place one layer of the reinforcement into the cookie sheet and pour a small amount of resin onto the center of the layer. Demolding can be aided by placing a small square of released plastic film under one edge of the first layer.
Work the resin into the reinforcement with the roller (for random mat), or plastic blade (for fabric). Work out from the center. Glass reinforcement will become less opaque as the resin wets the layer.
When one layer is fully wetted, lay the next against it and roller of blade the two together before adding additional resin. Add resin as before while working from the center outward.
Demolding:
Flex the cookie sheets until an edge of the hardened layup separates from the tool. If a plastic film tab was used, place a soft tool such as a plastic molding blade under this edge and pry. Do not use metal tools such as chisels, screw-drivers, etc.
Trim the part using a cutting tool used exclusively for composites. Ask the shop technician before cutting.