Scope of this Manual A revolutionary new polyester material and process technique has been developed that produces

a production and process-ready composite tool in typically 80% less time than conventional polyester tools. These tools, used in the production of open mold berglass hand lay-up/spray-up and resin transfer molding (RTM) parts, have for years required weeks of painstaking, labor intensive, hand lay-up of one or two layers at a time of resin-impregnated berglass mat reinforcement. This new material represents a breakthrough in reducing the lead time from concept design to part production. This manual documents the proper techniques and procedures in constructing composite molds made from Polylite Prole Tooling Polyester Resin and demonstrates the cost effectiveness of the resin compared to traditional polyester resins. Intended Audience

Introduction

Both pattern and tool makers will nd this manual useful in the construction of composite tools and prototype parts. Part Detailers, Industrial Designers and Engineers will also nd the manual informative in designing parts that are truly production ready. Reichhold Reichhold is the worlds largest supplier of unsaturated polyester & vinyl ester resins used by the automotive, boat-building, wind energy, industrial, corrosion, ame retardant, leisure and tool making industries. For further information about Reichholds product offerings contact your nearest Reichhold representative.

Copyright 2008, Reichhold Inc. All rights reserved.

Table of Contents

A1 A2

Polylite Prole System Advantages System Comparison

D1 D2D9

Tool Construction Technology Tool Construction TechnologySteps

B1 B2 B3 B4

Resin Compound Formulation System Recommendations Approved Application Equipment Approved Fillers | Approved Glass Reinforcement

E1E11

Trouble shooting

F1F2 F3

Typical Polylite Prole Resin Properties Typical Polylite Prole Resin Physical Properties

C1 C2 C3 C4 C5

Resin Compound Mix Proportions Promoter to Resin Mix Promoter Levels Versus Gel Time and Temperature Initiator Levels Versus Gel Time and Temperature Slave Arm Recalibration

G1G10

Technical Tips

H1H2

Casting

I1 I2 I3

Packaging / Safety / Quality / Storage Polylite Prole Distributors Corporate Headquarters


Polylite Prole 33540 Series is a non-promoted, non-thixotropic, unsaturated polyester laminating resin. Polylite Prole 33540 Series is suitable for construction of FRP tooling. The resin is formulated for room-temperature curing with Superox 46750 peroxide initiator and is to be used with specic alumina trihydrate llers. Polylite Prole 33540 Series must be promoted with Reichhold 46559 cobalt-based promoter solution prior to initiation. FEATURES Tools can be built in 80% less time BENEFITS

Polylite Prole System Advantages

33540 Series

Signicantly reduces labor costs Production start-up time reduced Makes prototype tools rapidly and economically Tool reproduces master exactly Resulting tool is stress free Print through and surface distortion eliminated Pre-release potential minimized Tool post-nishing reduced Tool demolds faster Built-in quality control indicator Lower composite cost Increased composite stiffness Improved heat transfer Consistent performance batch to batch

Low Shrinkage

Rapid Barcol hardness development Visual color change during cure Fillable to 50% with ATH

SPC/SQC Controlled

A1-a


Polyilte Prole 33541 Series is a promoted, non-thixotropic, unsaturated polyester laminating resin. Polyilte Prole 33541 Series is suitable for construction of FRP tooling. The resin is formulated for room-temperature curing with Superox 46750 peroxide initiator and is to be used with specic alumina trihydrate llers. FEATURES Tools can be built in 80% less time BENEFITS

Polylite Prole System Advantages

33541 Series

Signicantly reduces labor costs Production start-up time reduced Makes prototype tools rapidly and economically Tool reproduces master exactly Resulting tool is stress free Print through and surface distortion eliminated Pre-release potential minimized Tool post-nishing reduced Tool demolds faster Built-in quality control indicator Lower composite cost Increased composite stiffness Improved heat transfer No additional promoters needed Consistent performance batch to batch

Low Shrinkage

Rapid Barcol hardness development Visual color change during cure Fillable to 50% with ATH

Pre-Promoted SPC/SQC Controlled

A1-b


Polyilte Prole 33542 Series is a promoted, thixotropic, unsaturated polyester laminating resin. Polyilte Prole 33542 Series is suitable for construction of FRP tooling. The resin is formulated for room-temperature curing with Superox 46709 peroxide initiator or other approved peroxide initiators. FEATURES Tools can be built in 80% less time BENEFITS

Polylite Prole System Advantages

33542 Series

Signicantly reduces labor costs Production start-up time reduced Makes prototype tools rapidly and economically Tool reproduces master exactly Resulting tool is stress free Print through and surface distortion eliminated Pre-release potential minimized Tool post-nishing reduced Tool demolds faster Built-in quality control indicator Lower composite cost Increased composite stiffness Improved heat transfer No additional promoters needed Consistent performance batch to batch

Low Shrinkage

Rapid Barcol hardness development Visual color change during cure Pre-lled with ATH

Pre-Promoted SPC/SQC Controlled

A1-c


33540 Series

System Comparison |
33542 Series

33541 Series

This chart represents two major areas of benets using the Polylite Prole Tooling System versus standard resin used in production tooling. A typical tool can be produced at a system cost savings of approximately 50% compared to conventional laminating resins and tool making methods. The savings is passed on in both labor and materials. In addition to a system cost saving, a production time savings of up to 80% is also realized by using the Polylite Prole system.

100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% SYSTEM COST TOTAL TIME
Production time is reduced by 80% with Polylite Prole System System cost is reduced by 50% with the Polylite Prole System

I Standard
Non-Filled Resin

I All Polylite Prole

Tooling Systems

A2


COMPOUND Polylite Prole 33540 Series Resin Alumina Trihydrate Filler Reichhold 46559 Promoter Superox 46750 Peroxide Initiator Fiberglass Roving 100 parts 100 parts

Resin Compound Formulation

33540 Series

0.40.8 parts, based on resin weight 1.25 parts, based on resin weight 1822% of laminate weight

TYPICAL EXAMPLE When mixing a 55 gallon drum of resin (net weight 300 Ibs), the following formulation should be followed: Polylite Prole 33540 Series Alumina Trihydrate Filler Reichhold 46559 Promoter 300 lbs (136.08 kg) 300 lbs (136.08 kg) 1.5 lbs (.680 kg)

B1-a


COMPOUND Polylite Prole 33541 Series Alumina Trihydrate Filler Superox 46750 Peroxide Initiator Fiberglass Roving 100 parts 100 parts

Resin Compound Formulation

33541 Series

1.25 parts, based on resin weight 1822% of laminate weight

TYPICAL EXAMPLE When mixing a 55 gallon drum of resin (net weight 300 Ibs), the following formulation should be followed: Polylite Prole 33541 Series Alumina Trihydrate Filler 300 lbs (136.08 kg) 300 lbs (136.08 kg)

B1-b


COMPOUND Mix Requirements Polylite Prole 33542 Series Prelled & Promoted 100 parts Note: Superox 46709 Peroxide Initiatior is not to be mixed into the resin/ller mix but metered through the chopper gun. Superox 46709 Peroxide Initiator Fiberglass Roving

Resin Compound Formulation

33542 Series

1.25 parts, based on resin weight 1822% of laminate weight

TYPICAL EXAMPLE When mixing a 55 gallon drum of resin (net weight 300 Ibs), the following formulation should be followed: Polylite Prole 33542 Series 300 lbs (136.08 kg)

Polylite Prole must be agitated or mixed well to ensure even ller distribution. A bunghole mixer is not an acceptable mixer. A gear driven agitator or similar agitator/mixer for a 55 gallon drum is needed to properly mix Polylite 33542-25 before use.

B1-c


EQUIPMENT Airless, initiator injected spray-up chopper system Pressurized gun for gel coat application Air compressor Mixing tank with mixing blade Aluminum or plastic serrated roller Laminate thickness gauge Gelcoat thickness gauge Brush Scales Graduated cylinder OSHA approved canister-type respirator for paint and vapors Face shield or chemical goggles Impervious gloves Overalls or paper clean suit MATERIALS

System Recommendations
33540 Series

Polylite Prole 33540 Series, non-promoted, low shrink polyester tooling resin Alumina Trihydrate Filler Initiator, i.e. Superox 46750 Initiator Mold release agent Tooling gelcoat with appropriate initiator Continuous berglass gun roving or chopped strand mat. Core material, i.e. balsa wood Structural support materials, i.e. steel, wood Reichhold 46559 promoter solution

B2-a


EQUIPMENT Airless, initiator injected spray-up chopper system Pressurized gun for gel coat application Air compressor Mixing tank with mixing blade Aluminum or plastic serrated roller Laminate thickness gauge Gelcoat thickness gauge Brush Scales Graduated cylinder OSHA approved canister-type respirator for paint and vapors Face shield or chemical goggles Impervious gloves Overalls or paper clean suit MATERIALS

System Recommendations
33541 Series

Polylite Prole 33541 Series, promoted, low shrink polyester tooling resin Alumina Trihydrate Filler Superox 46750 Initiator Mold release agent Tooling gelcoat with appropriate initiator Continuous berglass gun roving or chopped strand mat. Core material, i.e. balsa wood Structural support materials, i.e. steel, wood

B2-b


EQUIPMENT Airless, initiator injected spray-up chopper system Pressurized gun for gel coat application Air compressor Mixing tank with mixing blade Aluminum or plastic serrated roller Laminate thickness gauge Gelcoat thickness gauge Brush Scales Graduated cylinder OSHA approved canister-type respirator for paint and vapors Face shield or chemical goggles Impervious gloves Overalls or paper clean suit MATERIALS

System Recommendations
33542 Series

Polylite Prole 33542 Series, promoted, lled, low shrink polyester tooling resin Superox 46709 Initiator Mold release agent Tooling gelcoat with appropriate initiator Continuous berglass gun roving or chopped strand mat. Core material, i.e. balsa wood Structural support materials, i.e. steel, wood

B2-c


MANUFACTURER VenusMagnum Division of PMC, Inc. 1862 Ives Avenue Kent, WA 98032 (206) 854-2660 Binks Manufacturing Company 9201 West Belmont Avenue Franklin Park, IL 60131-2887 (708) 671-3000 Graco Composites Equipment 8400 Port Jackson Ave. NW North Canton, OH 44720 330-494-1313 PRODUCT H.LS. PG 1116 Portable Chopper P21 Pump (11:1) with Abrasives Application Package SUGGESTED SPRAY TIPS 6503 6504

Approved Application Equipment |

33541 Series

33540 Series

33542 Series

SUGGESTED AIR PRESSURE SETTINGS 10 psi above non-lled settings

102-2400 Century Spray Gun Model 105-1 326 Portable Chopper B6-D (20:1) Pump

N/A

N/A

INDy or Formula System Pump (11:1) B-410/B-510 Chopper INDy or Formula Dispense Gun with Air Assist Containment (Internal or External Mix)

LPA2-147-5240 (Airless Tip) LPA2-147-5250 (Airless Tip) 23005-J5 (Non-Atomized Tip) 23005-J4 (Non-Atomized Tip)

Resin Atomized Air AAC

6070 psi 3540 psi 60 psi

B3


Approved Fillers
PRODUCT A-208 Alumina Trihydrate (Not used with 33452 Series) MANUFACTURER R. J. Marshall Company 26776 W. Twelve Mile Road Southeld, Ml 48034-7807 (800) 338-7900

Approved Fillers | Approved Glass Reinforcement

33540 Series

33541 Series

33542 Series

Approved Glass Reinforcement

PRODUCT Hybon 700 HTX MPM 112 oz chopped strand mat MPM 34 oz chopped strand mat MANUFACTURER PPG Industries, Inc. One PPG Place Pittsburgh, PA 15272 (412) 434-3250 Owens Corning Fiberglass Corporation Fiberglass Tower Toledo, OH 43659 (419) 248-8000

ME-3021 Roving

B4

Resin Compound Mix Proportions

33540 Series

33541 Series

This chart provides a reference a point for determining material mix proportions of Polylite Prole Tooling System and Alumina Trihydrate. For example, 300 lbs of Polylite Prole will require 300 lbs of Alumina Trihydrate ller.

1000 900 800 500 (226.80) 700 600 500 300 (136.08) 400 250 (113.40) 300 500 (226.80) 200 100 10 (4.54) 0 10 (4.54) 250 (113.40) 50 (22.68) 50 (22.68) 300 (136.08) I Polylite Prole
33540 and 33541 Series

I Alumina Trihydrate lbs (kg)

C1


This table will assist in calculating the correct quantity of Reichhold Promoter 46559 to be added to Polylite Prole 33540 Series resin. Resin Weight lbs (kg) 10 (4.54) 45 (20.43) 81.7 (87.9) 102.2 (109.8) 122.6 (131.8) 143.1 (153.7) 163.6 (175.6) 250 (113.40) 454.0 (488.2) 567.5 (610.2) 681.0 (732.3) 794.5 (854.3) 908.0 (976.3)

Promoter to Resin Mix

33540 Series

300 (136.08) 544.8 (585.8) 681.0 (732.3) 817.2 (878.7) 953.4 (1,025.2)

450 (204.12) 817.2 (878.7) 1021.5 (1,098) 1225.8 (1,318.) 1430.1 (1,537.3)

Promoter Solution @ 0.4% gm (ml) 18.2 (19.5) Promoter Solution @ 0.5% gm (ml) 22.7 (24.4) Warning Promoter Solution @ 0.6% gm (ml) 27.2 (29.3) Care must be taken to avoid direct mixing of any organic peroxide with metal soaps, amine, or any other polymerization accelerator or promoter. Violent decomposition will result if this is not followed. Promoter Solution @ 0.7% gm (ml) 31.7 (34.2) Promoter Solution @ 0.8% gm (ml) 36.2 (39.1)

1,089.6 (1,171.7) 1634.4 (1,756.6)

C2

 Promoter Levels Versus Gel Time and Temperature

33540 Series
This chart provides a reference point for determining the level of promoter to be used with a lled Polylite Prole resin system. For example, with an initiator level of 1.25%, Reichhold 46559 promoter level of .45%, will provide a gel time of approximately 18 minutes at 77F (25C). This chart show the variance temperature has on gel time at varied promoter levels.

Initiator @ 1.25% 46750 80 70 60 GEL TIME, MINUTES 50

+
I L

40
+

30
L I

20 10 0 0.00 0.20 0.25 0.35

L I L I L I L I L I L

90F (31.2C) 77F (25.0C) 65F (18.3C)

+
L

+ +

0.40

0.45

0.50

0.75

1.25

1.50

PROMOTER LEVEL %

C3

Initiator Levels Versus Gel Time and Temperature

33540 Series

This chart provides a reference point for determining the level of initiator to be used with a lled Polylite Prole resin system. For example, an initiator level of 1.25% (based on resin weight), at 65F (18.3C) will provide a gel time of approximately 39 minutes. This chart shows the variance temperature has on gel time at varied initiator levels for one type of system.

Promoted @ .45% 46559 80 70 60 GEL TIME, MINUTES

+ +
L

50 40
I L

30 20 10 0 0.50

+
L I I

90F (31.2C) 77F (25.0C) 65F (18.3C)

+
L I L L L

0.75

1.00

1.25

1.75

2.5

3.5

I N I T I AT O R L E V E L %

C4


33540 Series
Most application equipment dispenses materials using positive displacement pumps and mechanical slave-arms to ensure accuracy. Because peroxide initiator slave-arm adjustments are typically set for non-lled materials, recalibration is required to ensure proper metering. Note: Accurate equipment calibration should always be performed prior to use. This should be accomplished by independently dispensing, collecting and weighing the resin compound and peroxide initiator. This table provides general guidelines for the pump/slave-arm recalibration.

Slave Arm Recalibration

33541 Series

33542 Series

Resin/Filler Ratio 1:1 1:1 1:1 1:1

Slave-Arm Setting 0.75 1.00 1.25 1.50 1.75

% Superox 46750 (33540 and 33541) % Superox 46709 (33542) 1.14 1.51 1.90 2.30 2.70

Warning 1:1 Do not use Superox 46750 with the Polylite 33542 Series

C5


The spray-up process As in the hand lay-up process, a release agent followed by a sprayed-on gelcoat is rst applied to the master. When the gelcoat has cured according to the manufacturers instructions, the spray up process can begin. Prior to applying the lled tooling system, Reichhold recommends the application of a skin coat using our premium Hydrex resin. This skin coat should be applied at a minimum 0f 1.52 ounces of CSM or its equivalent. The next step in the spray-up process is to apply an initiated compound mist coat (no glass) of the tooling resin followed by spraying glass ber reinforcement and resin compound through a chopper gun. This gun simultaneously chops a continuous berglass roving into suitable length (typically 112 inches) and mixes initiator into the sprayed and lled resin compound. Shorter glass bers (12 inch ) can be used with smaller or complicated tools to minimize glass bridging in sharp corners. Additionally, long glass bers (2 inches) can be used in at tools or in tools that require higher strength.

Tool Construction Technology |

33541 Series

33540 Series

33542 Series

Use serrated rollers and brushes to remove air and thoroughly work the resin into the reinforcement. Several layers of chopped material or specialized reinforcement can be added to the laminate depending upon the requirements of the application. Again, as in hand lay-up, structural core materials can be incorporated within the laminate construction.

D1


Recommended Clean-up of Spray Equipment Mixing Guide per 100 lbs of Resin Polylite Prole 33540 and 33541 series Alumina Trihydrate Filler Reichhold 46559 Promoter (use with 33540) Superox 46750 Initiator (use with 33540 and 33541 series only) 100 lbs 100 lbs 0.5 lbs 1.25 lbs STEP 1MASTER PLUG

Tool Construction TechnologySteps

33540 Series

33541 Series

Regardless of the equipment used, the pumping system should be periodically ushed. It is recommended that clean, unlled neat resin be used for this process. Solvents should not be used as the initial ushing agent. Flushing rst with neat resin will remove or purge the lled resin from the pump. Then, if required, solvent can be used to ush the pump clean. To ensure good working conditions, follow manufacturers equipment recommendations for clean-up.

A. Construct master plug and nish to exact dimensions and surface smoothness B. Apply appropriate release agent to the surface (following manufacturers directions exactly).

D2-a


Recommended Clean-up of Spray Equipment Tooling System Components Polylite Prole 33542 Series Superox 46709 Initiator

Tool Construction TechnologySteps

33542 Series

Regardless of the equipment used, the pumping system should be periodically ushed. It is recommended that clean, unlled neat resin be used for this process. Solvents should not be used as the initial ushing agent. Flushing rst with neat resin will remove or purge the lled resin from the pump. Then, if required, solvent can be used to ush the pump clean. To ensure good working conditions, follow manufacturers equipment recommendations for clean-up.

STEP 1MASTER PLUG A. Construct master plug and nish to exact dimensions and surface smoothness B. Apply appropriate release agent to the surface (following manufacturers directions exactly).

D2-b


STEP 2RESIN COMPOUNDING Safety Requirements Always wear a face shield or chemical goggles along with impervious gloves to prevent skin contact with chemicals. A canister-type respirator must be worn to prevent the inhalation of vapors or spray mists.

Tool Construction TechnologySteps

33540 Series

A. Measure Polylite Prole 33540 Series accurately into a mixing container large enough to hold all materials needed for the compound. High-shear mixing container is not required. Note: Resin temperature and work area must be maintained at a minimum 65F (18.3C) to ensure complete cure. B. The quantity prepared should be of sufcient size to be used in eight hour period. Filler settling may occur; therefore, periodic or constant low-speed agitation is suggested. Should the mix be undisturbed for periods greater than four hours, remixing is recommended. C. Add required amount of Reichhold 46559 promoter solution to the unpromoted Polylite Prole 33540 series resin and begin low-speed agitation. See Figure 1. Note: do not let condensation drip into the resin. Refer to page C2 for suggested promoter levels. See Figure 2 for typical mixing blade and air motor. D. Mix at moderate speed for 2 minutes or until thoroughly mixed. Resin should have uniform color throughout mix with no promoter hanging on side of mixing container. E. Increase agitation to high speed and add alumina trihydrate ller at a steady rate. Blend ller until a 1:1 ratio of ller to resin is achieved. Scrape sides of the container to prevent ller from hanging to container sides. Refer to the chart on page C1 for mix proportions. F. Continue agitation at high speed for 10 minutes then agitate at low speed for 10 minutes to allow entrapped air to escape. G. Fill spray gun catalyzer system with Superox 46750 peroxide initiator. Make sure tank is clean to prevent contamination.

Figure 1

Figure 2

D3-a


STEP 2RESIN COMPOUNDING Safety Requirements Always wear a face shield or chemical goggles along with impervious gloves to prevent skin contact with chemicals. A canister-type respirator must be worn to prevent the inhalation of vapors or spray mists.

Tool Construction TechnologySteps

33541 Series

A. The quantity prepared should be a sufcient size to be used in an eight hour period. Filler settling may occur; therefore, periodic or constant low speed agitation is suggested. Should the mix be undisturbed for periods greater than four hours, remixing is recommended. B. Mix at moderate speed for 2 minutes or until thoroughly mixed. Resin should have uniform color throughout mix. C. Increase agitation to high speed and add alumina trihydrate ller at a steady rate. Blend ller until a 1:1 ratio of ller to resin is achieved. Scrape sides of the container to prevent ller from hanging to container sides. Refer to the chart on page C1 for mix proportions. See Figures 3 and 4. D Continue agitation at high speed for 10 minutes then agitate at low speed for 10 minutes to allow entrapped air to escape. E. Fill spray gun catalyzer system with Superox 46750 peroxide initiator. Make sure tank is clean to prevent contamination.

Figure 3

Figure 4

D3-b


STEP 2RESIN COMPOUNDING Safety Requirements Always wear a face shield or chemical goggles along with impervious gloves to prevent skin contact with chemicals. A canister-type respirator must be worn to prevent the inhalation of vapors or spray mists.

Tool Construction TechnologySteps

33542 Series

A. Remove the lid of the 33542 Series drum. Attach an appropriate mixer. B. Turn mixer on and agitate for 2030 minutes C. Fill spray gun catalyzer system with Superox 46709 peroxide initiator. Make sure tank is clean to prevent contamination. See Figures 5 and 6.

Figure 5

Figure 6

D3-c


STEP 3PRE-APPLICATION QUALITY CONTROL

Tool Construction TechnologySteps

33540 Series

33541 Series

33542 Series

A. After charging and adjusting the dispensing equipment, test to ensure that the proper gel and cure characteristics are achieved. B. Make a test laminate of equivalent cross-sectional thickness simulating the tool (120 mils minimum). Maintain a glass reinforcement content of 18-22% by weight. One and one half inch (38.1 mm) chopped glass is typically used, but this may vary to suit the application and end use requirement. See Figures 79. Make sure test panel is moved to a table for curing. C. If required, adjust the levels of either Superox 46750 (if using 33540 or 33541) or Reichhold 46559 promoter (if using 33540 or 33541) or Superox 46709 (if using 33542) to achieve the desired gel and cure time. Refer to pages C2 and C4 for assistance. D. Test laminate should reach a Barcol hardness of 25 within approximately 60 minutes after gelation.

Figure 7

Figure 8

STEP 4GEL COAT A. Spray on two or three wet passes of tooling gelcoat to develop a 30-40 mil (0.76-1 .02 mm) thickness and allow to cure to a tacky feel. See Figures 10. B. Follow all gelcoat manufacturers recommendations for handling and application.

Figure 9

Figure 10

D4


STEP 5FILLER PASTE APPLICATION (OPTIONAL) Paste Mix Formulation

Tool Construction TechnologySteps

33540 Series

33541 Series

33542 Series

A. Apply a skin coat, using Hydrex 33390 with a minimum of 1.52 0z of CSM. Resin Compound Fumed Silica/Milled Fibers Superox 46750 Initiator (use with 33450 and 33541 only) Superox 46709 Initiator (use with 33452 only) 40% (volume) 60% (volume) 1.25% (weight) B. If the master has sharp 90 llets or interior corners, fumed silica and/or milled bers can be mixed with the resin compound to form a paste. This paste can be applied to the back side of the skin coat. The paste is catalyzed with Superox 46750 Peroxide Initiator (if using 33540 and 33541), or Superox 46709 (if using 33542) thoroughly mixed and applied to the radius areas. This will minimize problems with air entrapment in the radii caused by glass bridging. Milled bers add additional strength to the mixture. The lled resin paste should be applied to a maximum cross-sectional thickness of 120 mils (3.05 mm). Do not allow the paste to cure before proceeding with the lamination. See chart Initiator Levels Versus Gel Time and Temperature on page C3 for gel time information. See Figures 1112.

1.25% (weight)

STEP 6LAMINATE APPLICATION A. Spray a mist coat of resin compound to an approximate thickness of 10 mils (0.25 mm). This should completely wet the surface. Only mist an area which can be worked prior to gelation. See Figure 13 B. A brush may be used to assist with resin coverage and removal of entrapped air.
Figure 11

C. Apply a ber-reinforced resin layer to approximate thickness of 3045 mils (0.76-1.14 mm) accomplished in one or two passes. See Figure 14.

Figure 12 Figure 13 Figure 14

D5


STEP 7ROLL OUT Warning Polylite Prole has been formulated to resist drainage and slippage on vertical surfaces when applied to a laminate thickness of 120-130 mils (3.05-3.30 mm). If laminate applications gel and harden but fail to achieve the characteristic light color, STOP the construction process and consult the trouble shooting guide or consult your Reichhold representative.

Tool Construction TechnologySteps

33540 Series

33541 Series

33542 Series

A. Remove all entrapped air with a brush or roller after each pass. Carefully inspect and remove air voids in laminate before proceeding to the next laminate application. Laminate applications must have a minimum thickness of 120 mils (3.05 mm) prior to gel and cure. See Figures 1517. B. Work out all entrapped air.

Figure 15

Figure 16

Figure 17

D6


STEP 8CURE

Tool Construction TechnologySteps

33540 Series

33541 Series

33542 Series

A. Allow the exotherm of each 120 mil (3.05 mm) laminate to subside before proceeding with subsequent applications. See Figure 18. Failure to do so will decrease the working time of subsequent laminations. Because in-service requirements of tools vary, it may be necessary to apply multiple laminates to achieve the desired cross-sectional thickness of the completed tool. B. Scuff sand with 60 grit sand paper, where required, to ensure void-free application of core reinforcement. C. Repeat Step 6, as needed, to achieve the required composite thickness. D. After each laminate application, trim excess glass from ange edge of the tool after partial cure is reached
Figure 18

STEP 9BACKUP CORE REINFORCEMENT A. Scuff sand with 60 grit sand paper, where required, to ensure void-free application of core reinforcement. See Figure 19. B. Tailor and cut core material to t. C. Pre-wet core material with resin compound on down side. D. Apply 120 mils (3.05 mm) of bed laminate. Applied in multiple wet passes.

Figure 19

D7


STEP 9BACKUP CORE REINFORCEMENT (CONT)

Tool Construction TechnologySteps

33540 Series

33541 Series

33542 Series

E. Apply core material to the tool. If using balsa with a scrim back, score with razor knife to aid in conformance to the bed laminate. Remove entrapped air under core mat. See Figure 20. F. Allow the core and bed laminate to cure before proceeding. Check for voids under the core and repair as required. G. Spray resin compound over core material. See gures 21-22. H. Spray chop over the core material until a total thickness of 120150 mils (3.053.81 mm) is reached. Achieve this thickness in multiple wet passes. I. Roll out all entrapped air.
Figure 20

J. Trim excess glass from the ange edge of tool after partial cure is reached.

Figure 21

Figure 22

D8


Note: Workplace temperature, materials temperature, promoter concentration and initiator concentration will inuence the cure rate of Polylite Prole. A minimum Barcol 934-1 value of 45 should be achieved prior to removing the tool from the master.

Tool Construction TechnologySteps

33540 Series

33541 Series

33542 Series

STEP 10ADD BACK-UP REINFORCEMENT STRUCTURE A. Cut and tailor a backup structure as required to maintain proper support. B. Scuff sand attachment points on the tool as required to ensure a proper t. C. Position structure on the tool and attach by spraying chop around each attachment point. See gure 23. D. Roll out any entrapped air.

STEP 11REMOVE MASTER A. Allow to cure for a minimum of 24 hours before removing the tool from the master. B. Remove the tool from the master. See Figure 24.

Figure 23

STEP 12APPLY RELEASE AGENT A. Prepare tool with appropriate release agent. Follow all manufacturers instructions.

Figure 24

D9


Defect: Slow Cure Description: Laminate takes excessive amount of time to develop hardness CAUSES 1. Low resin and/or workplace temperature 2. Low peroxide initiator levels CORRECTIVE ACTION

Trouble Shooting
33540 Series

Maintain work area, master and resin compound temperature of 85F minimum. Maintain a minimum level of 0.8% by volume or 0.6% by weight of Superox 46750 Peroxide Initiator based on resin. Recalibrate dispensing equipment. Maintain promoter level of 0.41.0% by weight. Use 46559 promoter Replace with dry ller.

3. Thin laminate 4. Wet ller

Defect: Delamination Description: separation of the composite occurring between laminate layers. CAUSES 1. Resin-rich surface CORRECTIVE ACTION Remove excess resin from laminate surface before applying next layer. Abrade surface using 60 grit sand paper. Remove dust or other contamination from laminate surface before applying next laminate. Maintain correct promoter and initiator levels. Do not interrupt lamination for extended periods of time or expose non-completed parts to excessive heat or sunlight.

2. Contamination of the laminate surface 3. Laminate under cured 4. Excessive laminate cure

E1-a


Defect: Slow Cure Description: Laminate takes excessive amount of time to develop hardness CAUSES 1. Low resin and/or workplace temperature 2. Low peroxide initiator levels CORRECTIVE ACTION

Trouble Shooting |
33542 Series

33541 Series

Maintain work area, master and resin compound temperature of 85F minimum. Maintain a minimum level of 0.8% by volume or 0.6% by weight of Superox 46709 or 46750 Peroxide Initiator based on resin. Recalibrate dispensing equipment. Maintain thickness of 120 mils (3.05 mm) for each laminate application. Replace with dry ller (33541)

3. Thin laminate 4. Wet Filler

Defect: Delamination Description: separation of the composite occurring between laminate layers. CAUSES 1. Resin-rich surface CORRECTIVE ACTION Remove excess resin from laminate surface before applying next layer. Abrade surface using 60 grit sand paper. Remove dust or other contamination from laminate surface before applying next laminate. Maintain correct initiator levels. Do not interrupt lamination for extended periods of time or expose non-completed parts to excessive heat or sunlight

2. Contamination of the laminate surface 3. Laminate under cured 4. Excessive laminate cure

E1-b


33540 Series
Defect: Poor wet-out / workability Description: Saturation of glass bers is difcult CAUSES 1. Filler content of mix is too high (Does not apply to 33542 Series) CORRECTIVE ACTION

Trouble Shooting |
33542 Series

33541 Series

Reduce ller content down to 45% minimum through addition of more Polylite Prole 33540 or 33541 Series. Agitate mix to prevent settling of ller. Increase resin line pressure, reduce chopper speed and increase diameter of resin tip. Adjust spray angle to ensure complete glass to resin overlap. Re-wet laminate with lled resin mix after each application of laminate. Switch to glass with a binder and/or sizing with better solubility. Use only recommended reinforcements.

2. High glass to resin ratio 3. Resin from gun does not wet-out chop

4. Incompatible glass binder or sizing

Defect: Orange Peel surface nish Description: Irregular surface to the gel coat which has the surface texture of an orange FCAUSES 1. Gel coat not fully cured when skin coat is applied CORRECTIVE ACTION Switch to faster curing gel coat. Allow more time for gel coat to cure. Increase work-area temperature and materials. Increase peroxide initiator level in resin. Maintain 1.02.0% based on resin. Increase work area temperature. Check for moisture in ller. Recalibrate dispensing equipment. Replace or renish master mold. Apply mist coat and roll out air in skin coat. Adjust gelcoat application and/or consult gelcoat manufacturer.

2. Long resin gel time allows styrene in skin coat resin to soften gel coat

3. Orange peel imprint in tool 4. Air voids in skin coat 5. Excessive orange peel during application of tooling gel coat

E2


33540 Series
Defect: Blisters Description: Blisters forming on the surface of the part. The blister may or may not contain a liquid. CAUSES 1. Contamination in resin 2. Air voids in skin coat CORRECTIVE ACTION Inspect resin and air line for contamination (such as oil).

Trouble Shooting |
33542 Series

33541 Series

Reduce rst berreinforced resin layerto an approximate thickness of 2030 mils. Remove entrapped air before proceeding to the next laminate application. Laminate applications must have a minimum thickness of 120 mils (305 mm) prior to gel and cure. Use 14 inch long chop in rst 2030 mils of skin coat. Reduce ller content to 45% by weight. Run 6 blades in chopperalternate and inch glass in rst 20-30 mils of skin coat. Chop one strand of roving. Adjust chopper motor speed to maintain proper resin to glass ratio. Adjust resin to glass fan to ensure uniform wet out and composition. Maintain resin compound temperature at 2932 (85 5F). Use brush to assist with wet out. Roll laminate using brissel type or bubble buster roller. Inadequate mixing of additives during application. Review mixing procedure described in tooling manual.

3. Peroxide initiator droplets (blister often contains liquid with a vinegar odor) 4. Inadequate mixing of peroxide initiator

Make sure the peroxide initiator ow stops when the trigger on the gun is released. . Keep gun tip clear Adjust or modify mixing capabilities of equipment. Visually inspect laminate to ensure uniform mixing after initial catalyzation.

E3


Defect: Sagging (Sliding) Description: Non-gelled laminate slides down the vertical surface of the master. This causes a ripple to form in the laminate. CAUSES 1. Excessive laminate thickness 2. Glass content is too low 3. Excessive laminate gel time 4. Mist coat too thick CORRECTIVE ACTION Do not apply more than 150 mils (3.81 mm) of laminate in one application. Maintain glass content of 1822%. Maintain proper temperature and levels of peroxide initiator and promoter.

Trouble Shooting
33540 Series

Maintain mist coat thickness to 10 mils (.25 mm) or less, especially on vertical surfaces.

Defect: Spotty Cure Description: Some areas of the laminate will gel and cure faster than other areas. In extreme cases, areas of the laminate may never cure. CAUSES 1.Poor mixing of the peroxide initiator CORRECTIVE ACTION Adjust equipment to ensure peroxide initiator in uniformly mixing with resin. Check viscosity of lled resin mix. Ensure dispensing equipment is suitable for lled resin system. Use different ller, glass or resin. Inspect lines and lters for contamination or restrictions. Inspect glass for contamination and/or moisture content. Use only Superox 46750. Use of other peroxide initiators can inhibit gel and/or cure. Maintain 0.41.0% 46559 promoter and 1.02.0% 46750 catalyst. Concentrations are based on resin content and are by weight. The laminate will always cure faster in thick and resin-rich areas. To avoid variations in thickness, the gun operator needs to make long sweeping motions when chopping. Frequently monitor laminate thickness in various locations on the part. Maintain a minimum thickness of 120 mils (3.05 mm).

2. Contamination of resin, ller or glass reinforcement

3. Improper peroxide initiator used 4. Improper levels of promoter or peroxide initiator.

5. Uneven laminate thickness

E4-a


Defect: Sagging (Sliding) Description: Non-gelled laminate slides down the vertical surface of the master. This causes a ripple to form in the laminate. CAUSES 1. Excessive laminate thickness 2. Glass content is too low 3. Excessive laminate gel time 4. Mist coat too thick CORRECTIVE ACTION Do not apply more than 150 mils (3.81 mm) of laminate in one application. Maintain glass content of 1822%. Maintain proper temperature and levels of peroxide initiator.

Trouble Shooting |
33542 Series

33541 Series

Maintain mist coat thickness to 10 mils (.25 mm) or less, especially on vertical surfaces.

Defect: Spotty Cure Description: Some areas of the laminate will gel and cure faster than other areas. In extreme cases, areas of the laminate may never cure. CAUSES 1.Poor mixing of the peroxide initiator CORRECTIVE ACTION Adjust equipment to ensure peroxide initiator in uniformly mixing with resin. Check viscosity of lled resin mix. Ensure dispensing equipment is suitable for lled resin system. Use different ller, glass or resin. Inspect lines and lters for contamination or restrictions. Inspect glass for contamination and/or moisture content. Use only Superox 46750 (with 33541 only) or 46709 (with 33542 only). Use of other peroxide initiators can inhibit gel and/or cure. Maintain a minimum temperature of 85F The laminate will always cure faster in thick and resin-rich areas. To avoid variations in thickness, the gun operator needs to make long sweeping motions when chopping. Frequently monitor laminate thickness in various locations on the part. Maintain a minimum thickness of 120 mils (3.05 mm).

2. Contamination of resin, ller or glass reinforcement

3. Improper peroxide initiator used

4. Low temperature in work area or of materials 5. Uneven laminate thickness

E4-b


33540 Series
Defect: Air entrapment/laminate voids Description: Air pockets in cured laminate CAUSES 1.Improper roll-out or excessively thick CORRECTIVE ACTION

Trouble Shooting |
33542 Series

33541 Series

Roll out between each 2040 mils (0.511.2 mm) application of chop. Roll out using moderate speed and pressure. Review causes under Drainage. See page E6-a Retest lled viscosity. Recalculate resin and ller addition. Maintain 1 to 1 ratio by weight. Reduce ller content to 45% minimum. Increase lled resin mix temperature to 7080F (21.126.7C). Do not add additional monomers. Only Polylite 33540 or 33541 Series may be added to restore proper llerto-resin ratio. Maintain proper resin mix-to-glass ratio. Pre-wet part with lled resin prior to application of laminate. Decrease peroxide initiator to minimum of 0.6% by weight or 0.8% by volume. Do not reduce promoter content below 0.4% by weight.

2. Drainage from low viscosity leaves air voids 3. High viscosity (Does not apply to 33542 series)

4. Resin-starved areas 5. Short gel time does not allow glass wet-out to be completed

Defect: Pre-release lines Description: Pre-release lines are wavy areas typically formed where the surface of parts has released slightly from the mold CAUSES 1. Improper application of gel coat and/or mold preparation CORRECTIVE ACTION Follow manufacturers recommendations. Maintain a uniform gel coat thickness of 1830 mils (0.460.76 mm) dry.

E5


33540 Series

Trouble Shooting |
33542 Series

33541 Series

Defect: Drainage Description: The resin drains out of the laminate on vertical surfaces forming puddles on the bottom and dry glass on the top. (Excessively large puddles of resin may cause heat lines and/or pre-release.) CAUSES 1.High resin compound mix-to-glass ratio 2. Low viscosity or thixotropic index 3. High resin temperature 4. Long laminate gel time CORRECTIVE ACTION Lower resin line pressure or increase chopper speed on gun. Maintain 41% resin/41% ller/ 18% glass. Maintain resin to ller ratio of 1 to 1. Use only specic llers recommended. By cooling resin to 70 80F (21.126.7C), viscosity will be increased. Use only recommended type and levels of peroxide initiator and promoters (if using 33540). Recalibrate dispensing equipment. Review causes under Slow Cure and Spotting Cure pages E1-a & b. Recalculate ller content and if required adjust to 50% by weight. Mix drum to re-disperse ller. Use only recommended llers.

5. Filler drop-out in resin

Defect: Resin weeping Description: Droplets of liquid resin penetrating through gelled laminate CAUSES 1. Inadequate mixing of peroxide initiator CORRECTIVE ACTION For external mix, use a tip that gives the proper degree of fan to allow for complete mixing. For internal mix, use different static mixer or use extension with air assist Use only recommended type and concentration of promoters and peroxide initiators. Ensure dispensing equipment is suitable and in proper operating condition.

2. Low peroxide initiator and/or promoter concentration. This results in under-cured or non-cured substrate laminates

E6


33540 Series
Defect: No laminate color change Description: Laminate fails to turn white upon curing CAUSES 1. Low exotherm CORRECTIVE ACTION

Trouble Shooting |
33542 Series

33541 Series

Maintain minimum thickness of 120 mils (3.05 mm) for each cure cycle. Maintain minimum material temperature of 85F. Maintain recommended peroxide initiator and promoter concentration. lnspect equipment for restrictions. Maintain 1-2% Superox 46750 or 46709 peroxide based on resin used. Check gun for proper mixing of peroxide initiator.

2. Low peroxide level 3. Poor peroxide mixing

Defect: Tool sticking on master Description: Tools are difcult to remove from master after cure. CAUSES 1. Improper or inadequate preparation of master CORRECTIVE ACTION Use proper release agents. Reapply release agent to master. Apply a parting lm (PVA). Employ mold maintenance program. Use extra layers of wax or parting lm (PVA). Follow mold release agent manufacturers recommendations. 2. Design of the master 3. Over spray or other foreign material on master before gel coat is applied 4. Articial vacuum between master and mold Eliminate reverse drafts or insufcient drafts in master. Keep master protected when not in use. Clean and inspect prior to use. Break with compressed air. Design master with poppets in required areas.

E7


33540 Series
Defect: Fiber print through Description: Individual glass bers can be seen through gel coat CAUSES 1. Laminate exotherm is too low CORRECTIVE ACTION

Trouble Shooting |
33542 Series

33541 Series

Maintain minimum thickness of 120 mils (3.05 mm). for each cure cycle. Maintain and materials at 85F or higher. Based on resin content, increase Superox 46-750 (33540 or 33541) or Superox 46-709 (33542) peroxide initiator to 12%. Ensure gel coat application conforms to manufacturers recommendation. Switch to faster curing gel coat. Allow more time for gel coat to cure. Increase plant and/or master temperature. Increase peroxide initiator concentration. Increase plant/materials temperature. Follow manufacturers recommendations. Replace or renish master. Discard resin.

2. Gel coat not fully cured when laminate is applied

3. Long gel time allows styrene to soften gel coat 4. Gel coat is too thin 5. Fiber print pattern in master 6. Excessive shrinkage. Polylite Prole resin contaminated with other polyester resins

Defect: Post cure Description: The appearance of ber or roving print through after the part has been demolded CAUSES 1. Slow cure 2. Part demolded before properly cured 3. Insufcient gel coat cure or thickness CORRECTIVE ACTION Review causes under Slow Cure and Spotty Cure. See pages E1-a, E4-a & b Do not demold until part has achieved a minimum Barcol hardness of 45. Ensure proper application. See causes under Fiber print through above.

E8


33540 Series
Defect: Blisters Description: Blisters forming on the surface of the part. The blister may or may not contain a liquid. CAUSES 1. Cracks 2. Cracks of various lengths occur in close proximity to radius areas. Commonly occurs after second or third forming cycle. CORRECTIVE ACTION Inspect resin and air line for contamination (such as oil).

Trouble Shooting |
33542 Series

33541 Series

Reduce rst berreinforced resin layerto an approximate thickness of 2030 mils. Remove entrapped air before proceeding to the next laminate application. Laminate applications must have a minimum thickness of 120 mils (305 mm) prior to gel and cure. Use 14 inch long chop in rst 2030 mils of skin coat. Reduce ller content to 45% by weight. Run 6 blades in chopperalternate and inch glass in rst 20-30 mils of skin coat. Chop one strand of roving. Adjust chopper motor speed to maintain proper resin to glass ratio. Adjust resin to glass fan to ensure uniform wet out and composition. Maintain resin compound temperature at 2932 (85 5F). Use brush to assist with wet out. Roll laminate using brissel type or bubble buster roller. Inadequate mixing of additives during application. Review mixing procedure described in tooling manual.

3. Droplets (blister often vinegar odor) 4. Peroxide Initiator.

Make sure the peroxide initiator ow stops when the trigger on the gun is released. Keep gun tip clear. Adjust or modify mixing capabilities of equipment. Visually inspect laminate to ensure uniform mixing after initial catalyzation.

E9


33540 Series
Defect: Air entrapment/laminate voids Description: Air pockets in cured laminate CAUSES 1. Improper roll-out or excessively thick CORRECTIVE ACTION Roll out between each 20-40 mils (0.51 - 1.2 mm) application of chop. Roll out using moderate speed and pressure. Review causes under Drainage. Consult page E6.

Trouble Shooting |
33542 Series

33541 Series

2. Drainage from low viscosity leaves air voids 3. High viscosity

Retest lled viscosity. Recalculate resin and ller addition. Maintain 1 to 1 ratio by weight. Reduce ller content to 45% minimum. Increase lled resin mix temperature to 7080F (21.126.7C). Do not add additional monomers. Only Polylite 33540 Series may be added to restore proper ller-to-resin ratio. Maintain proper resin mix-to-glass ratio. Pre-wet part with lled resin prior to application of laminate. Decrease peroxide initiator to minimum of 0.6% by weight or 0.8% by volume. Do not reduce promoter content below 0.4% by weight.

4. Resin-starved areas 5. Short gel time does not allow glass wet-out to be completed

E10


33540 Series
Defect: Cracks Description: Cracks of various lengths occur in close proximity to radius areas. Commonly occurs after second or third forming cycle. CAUSES 1. Pre use microcracking. Excessive force 2. Used during demolding tool from master CORRECTIVE ACTION Redesign master plug to ensure sufcient.

Trouble Shooting |
33542 Series

33541 Series

Draft angles. Renish and or apply release agents to master. Rigidize tool to prevent exing. Reduce air pressure used to assist demold.

Defect: Cracks Description: Various lengths which may occur either in localized areas or throughout the tool. CAUSES 1. Excessive gelcoat thickness 2. Inconsistent gelcoat thickness 3. Thermal shock. Tool exposed to wide temperature differentials 4. Gelcoat too rigid 5. Incomplete cure of gelcoat 6. Thermoforming cycle time too long. CORRECTIVE ACTION Reduce cured gelcoat thickness to .007.012 (0.180.305 mm). Use thickness gauge during application Warm tool prior to production. Avoid exposing (storing/staging) hot tools to extreme cold. Use tougher, higher elongation gelcoat. Consult with gelcoat manufacturer to ensure proper selection. Follow manufactures applications instruction. Reduce cycle times; balance vacuum throughout tool. Heat acrylic sheet evenly. Faster cool down of formed acrylic sheet. Reduce cycle times. Heat acrylic sheet evenly to avoid hot spots.

7. Uneven thermal expansion of gelcoat.

E11


Neat resin tested at 77 F ( 25 C )

Typical Polylite Prole Resin PropertiesNeat

33540 Series

33541 Series

PROPERTIES Flash Point, Seta Closed Cup Shelf Life, Minimum % Styrene Monomer Weight/Gallon Viscosity, Brookeld Model LVT, #1 Spindle @ 30 RPM Gel Time, 1.25% Superox 46750 Peroxide Initiator and 0.5 parts 46559 Polylite promoter by weight Time to Peak Peak Temperature Color, Liquid

UNITS F (C)

TEST METHOD

VALUES 89 (31.7)

Months

N/A 18-001

3 47.5 8.8 120 (3.99)

lb cps

(kg)

18-030 18-021

Minutes

18-050

25

Minutes F (C)

18-050 18-050 18-043

33 415 (212.8)

Clear Amber

F1


Resin reinforced with 20% chopped glass bers and tested at 77 F ( 25 C ) PROPERTIES Gel Time Cup Values Time to Peak Peak Temperature Viscosity, Brookeld Model LVF #3 Spindle @ 60 RPM Weight/Gallon Linear Mold Shrink Specic Gravity Tensile Str. Yield Flexural Str. Yield Elongation @ Break Tensile Modulus Compressive Str lzod, Notched, R.T. Barcol Hardness Linear Therm Expan in/in F (cm/cm C) lb/in2 lb/in2 1% lb/in2 lb/in2 ft lb/in (kg/cm2) (kg/cm2) (kg cm/cm) (kg/cm2) (kg/cm2) UNITS minutes minutes F cps (C) 18-021 TEST METHOD

Typical Polylite Prole Resin Properties

33540 Series

33541 Series

33542 Series

VALUES

See Promoter Levels Versus Gel Time and Temperature Chart on page C3

850

lbs in/in

(kg) (cm/cm)

18-030

12.3 0.0002

(5.58) (0.0002)

ASTM D792 ASTM D638 ASTM D790 ASTM D638 ASTM D638 ASTM D695 ASTM D256 934-1 ASTM D696

1.48 7,500 14,000 1.0 15.3 x 105 19,500 29.9 50 1.2 x 106 (2.16 x 106) (1.08 x 105) (1370) (5.5) (527) (984)

F2


The following table shows the physical test results using three ller and glass combinations. PHYSICAL PROPERTY EVALUATION

Typical Polylite Prole Resin Physical Properties

33540 Series

33541 Series

33542 Series

A Tensile Strength, psi Flexural Strength, psi % Elongation Tensile Modulus, psi Flexural Modulus, psi Izod IMpact Strength, Notched 8.58 x 103 1.49 x 104 1.76 9.96 x 105 7.58 x 105 11.5 ft 1b/in

B 1.10 x 104 1.91 x 104 2.09 1.04 x 106 9.58 x 105 9.8 ft 1b/in

C 1.47 x 104 2.11 x 104 2.67 1.059 x 106 8.84 x 105 10.1 ft 1b/in

LAMINATE CONSTRUCTION % Glass Content % ATH content % Polylite Prole Tooling System 20 50 30 26.7 45 28.3 26.5* 40 33.5

*Resin was not able to wet out more glass.

F3


33540 Series
SYMPTOM Air Voids in Skin Coat. REMEDY

Technical Tips |
33542 Series

33541 Series

Reduce rst berreinforced resin layerto an approximate thickness of 2030 mils. Remove entrapped air before proceeding to the next laminate application. Laminate applications must have a minimum thickness of 120 mils (3.05 MM) prior to gel and cure. Use 14 inch long chop in rst 2030 mils of skin coat. Reduce ller content to 45% by weight. (For 33540 and 33541 series only). Run 6 blades in chopperalternate 14 and 12 inch glass in rst 2030 mils of skin coat. Chop one strand of roving. Adjust chopper motor speed to maintain proper resin to glass ratio. Adjust resin to glass fan to ensure uniform wet out and composition Maintain resin compound temperature at 2932 (85 5F). Use brush to assist with wet out. Roll laminate using brissel type or bubble buster roller. Inadequate mixing of additives during application. Review mixing procedure described in tooling manual.

Air Voids in Pinch Area of Tool, 90 Corners or Small Deep Draw Areas

Thoroughly wet out a sufcient quantity of glass roving with catalyzed resin compound. Place in radii area. Remove entrapped air. Do not allow to gel and cure before applying primary laminate. Use ller paste. Consult page D5.

G1


33540 Series
SYMPTOM Improved Sprayability REMEDY Maintain resin compound temperature at 29 (85 5F) Reduce ller content to 45% by weight. (For 33540 and 33541 Series only ) Convert pump pick-up tube from 34 inch to 1 inch diameter.

Technical Tips |
33542 Series

33541 Series

Remove ne mesh lters from pump pick-up tube and other in-line resin lters. Replace with 6080 mesh lters. Adjust and clean application equipment. At end of each day ush equipment with non-lled Prole resin. Leave pump piston on the down strokehelps to avoid possible buildup of ller on pump shaft. Long Compound Gel Time Verify concentration and weights of resin, ller, promoter and peroxide initiator. Maintain FIFO inventory. Increase Reichhold 46559 promoter to a maximum level of 1.0% by weight. (For 33540 Series only). Warm resin compound to 29 (85 5F). Mix 46559 promoter into resin for a longer period of time: 510 minutes. Conrm and use only approved llers. Use different lot of ller.

G2


SYMPTOM Short Gel Time Resulting From Elevated Work Place Temperatures Laminate Slippage REMEDY Reduce amount of Reichhold Promoter (33540) and or initiator (33540 and 33541). Disperse ller using a Cowls mixing blade.

Technical Tips |
33541 Series

33540 Series

Adjust ller content to 45% by weight and add up to 0.25% by weight fumed silica. Maintain a 10 mil or less mist coat of resin compound. Conrm that only approved llers are in use. Inadequate Mixing of Initiator or Initiator Streaking Equipment not adjusted properly or in need of cleaning or repair. Take appropriate action. Warm resin compound to 29C32C (85F90F). Inspect turbulent mixer used in equipment. Replace with new or more efcient unit. In some equipment a nylon unit performs better that teon. Teon soft enough that utes can collapse, causing a loss of seal to the chamber and initiator streaming or improper mixing. Cured Laminate Has Green Colored Surface Over catalyzation. Repair or adjust dispensing equipment. Review tooling manual for suggested concentration. Wrong peroxide initiator used. Use only Superox 46750.

G3-a


SYMPTOM Short Gel Time Resulting From Elevated Work Place Temperatures Laminate Slippage REMEDY Reduce amount of initiator. Disperse ller using a Cowls mixing blade. Maintain a 10 mil or less mist coat of resin compound. Conrm that only approved llers are in use. Inadequate Mixing of Initiator or Initiator Streaking

Technical Tips
33542 Series

Equipment not adjusted properly or in need of cleaning or repair. Take appropriate action. Warm resin compound to 29C32C (85F90F). Inspect turbulent mixer used in equipment. Replace with new or more efcient unit. In some equipment a nylon unit performs better that teon. Teon soft enough that utes can collapse, causing a loss of seal to the chamber and initiator streaming or improper mixing.

Cured Laminate Has Green Colored Surface

Over catalyzation. Repair or adjust dispensing equipment. Review tooling manual for suggested concentration. Wrong peroxide initiator used. Use only Superox 46709.

G3-b


SYMPTOM Surface Distortion of completed Tool or Part REMEDY Increase temperature of work place and master part. Verify concentration and weights of resin, ller, promoter and peroxide initiator.

Technical Tips |
33541 Series

33540 Series

Inadequate mixing of additive materials. Review mixing procedures and adjust dispensing equipment. Brush or roll mist coat of resin compound. Over-catalyzation /under-catalyzation. Review manual and make necessary adjustments or equipment repairs. Warm resin compound to 2932C (8590). Maintain temperature during application. Increase work place temperature. Improper or inadequate gelcoat cure. Consult manufacturer. Wrong peroxide initiator used. Use only Superox 46750. Raise laminate exotherm by increasing cross sectional thickness of laminate prior to gel and cure.

G4-a


SYMPTOM Surface Distortion of completed Tool or Part REMEDY Increase temperature of work place and master part. Verify concentration and weights of resin and peroxide initiator.

Technical Tips
33542 Series

Inadequate mixing of additive materials. Review mixing procedures and adjust dispensing equipment. Brush or roll mist coat of resin compound. Over-catalyzation /under-catalyzation. Review manual and make necessary adjustments or equipment repairs. Warm resin compound to 2932C (8590). Maintain temperature during application. Increase work place temperature. Improper or inadequate gelcoat cure. Consult manufacturer. Wrong peroxide initiator used. Use only Superox 46709. Raise laminate exotherm by increasing cross sectional thickness of laminate prior to gel and cure.

G4-b


33540 Series
SYMPTOM Low Laminate Mechanical Properties REMEDY Correct and conrm that proper initiator and concentration are used. Increase temperature of work place and resin compound during application.

Technical Tips |
33542 Series

33541 Series

Reduce ller content to 45% by weight and increase content of glass reinforcement. (For 33540 and 33541 Series only). Incorporate uni-directional and/or bi-directional glass. Increase length of chopped glass. Increase thickness of nal laminate. Cracked Flange Area of Tool Reduce air in skin coat. Hand lay uni-directional and/or bi-directional glass. Increase cross sectional thickness of ange with composite. Reduce ller content to 45% by weight and increase content of glass reinforcement. Increase length of chopped glass.

G5


33540 Series
SYMPTOM StickingTool to Master, or Part to Tool REMEDY

Technical Tips |
33542 Series

33541 Series

Misapplication of materials used to construct masterfollow manufacturers recommendation. Use PVA parting lm. Design the master or part with proper draft angles. Inadequate gelcoat cure. Follow manufactures recommendation. (This can also appear as hazing of gelcoat.) Gelcoat porosityreview and correct application techniques. Improper or inadequate use of release agents. Follow manufacturers application recommendations.

RepairsSecondary Bond

Thoroughly abrade with 60 grit sand paper and clean. Warm Polylite Prole Series resin compound to 2932 C (85 90 F). Use chopped and bi- or uni-directional glass. Use step shingle laminate extending at minimum of 6 inches from edge of repair. Prepare surface with Atprimefollow directions for use.

Poor, or Lack of, Adhesion to PVC Core Material

PVC core materials have not been evaluated for use with Polylite Prole and are therefore not recommended at this time.

G6


33540 Series

Technical Tips |
33542 Series

33541 Series

The following table will assist the Polylite Prole user to estimate the amount of material required for a given thickness of composite. Values are based on pounds per square foot of composite which incorporate a 1:1 ratio resin to ller and 19% by weight chopped continuous strand roving. The term composite refers to resin, ller and chopped strand roving content only.

Thickness (mils) Thickness (inches) Composite, weight Resin, weight, (lbs) Filler, weight, (lbs) Glass, weight, (lbs)

1.000 1 8.15 3.30 3.30 1.55

.8750
7

.7500
3

.6250
5

.5000
1

.3750
3

.2500
1

.1250
1

7./13 2.88 2.88 1.37

6.11 2.48 2.48 1.15

5.10 2.04 2.04 1.02

4.08 1.64 1.64 0.80

3.06 1.23 1.23 0.60

2.04 0.82 0.82 0.40

1.02 0.41 0.41 0.20

Note: Add approximately 10% for waste

G7


33540 Series
Thermoformed Acrylic Tool Fabrication

Technical Tips |
33542 Series

33541 Series

This guide is intended to assist the fabricator with construction of Polylite Prole tools which will be used to thermoform either cast or extruded acrylic sheet. Only tools fabricated by glass reinforced spray-up techniques will be reviewed. The guide was compiled from information provided by fabricators and material suppliers. This information represents current state-of-the-art at the time of printing and is intended for guidance purposes. Final design, application and material selection is the sole responsibility of the fabricator. Because construction materials differ among composition, application and performance, and due to a variety of thermoforming process conditions, we recommend each user thoroughly evaluate this tooling system for suitability. STEP 1 Prior to fabrication, read, view and understand Reichholds tooling manual and video. Read and understand all product literature and material safety data sheets.

STEP TWOMASTER PLUG A. Construct master plug and nish to exact dimensions and surface smoothness. B. Apply appropriate release agent to the surface (following manufacturers directions exactly).

STEP 3 A. Review the Resin Compounding and Pre-Application Quality Control sections, pages B1-D4.

G8


33540 Series

Technical Tips |
33542 Series

33541 Series

STEP 4GEL COAT A. Spray on two or three passes of a suitable gel coat to develop a 712 mu (0.20.3 mm) thickness. Thickness of over 12 mu (0.3mm) may result in cracking. Spraying gel coat to a uniform thickness onto small irregular molds can be difcult. A combination of low spray pressure and small diameter spray tips is suggested. Allow to cure to a tacky feel. An external heat source may be required to ensure that proper degree of cure is achieved. B. The use of tough heat resistant gel coats are suggested. These include vinyl ester (aluminum and non-aluminum lled) and isophthalic/neopentyl glycol based products. C. Follow all gel coat manufacturers recommendations for handling and applications. NOTE: The fabricator may elect not to employ a gel coat. It may be advantageous to eliminate the gel coat when fabricating small irregular shaped molds or molds that are subjected to temperatures over 176C (350F). If a gel coat is not used, a one to two ply 1.5 oz. per square foot Hydrex Series laminate may be used.

STEP 5NON FILLED PRIMARY LAMINATE (OPTIONAL) A. To minimize the potential of air entrapment within the primary laminate, a non-lled laminate may be applied after the gel coat step. This laminate should be applied to a thickness of 17.535 mils (0.440.89 mm) using Hydrex 33390 vinyl ester hybrid or Polylite 33346 vinyl ester resin. A resin to glass ratio of 7075:3025 should be maintained. The primary laminate should be permitted to cure 24 hours prior to laminating with the Polylite Prole system. Read and understand both the product bulletin and material safety data sheet prior to using Hydrex 33390.

STEP 6LAMINATE APPLICATION A. Spray a mist coat of resin compound to an appropriate thickness of 10 mils (0.25 mm). This should completely wet the surface. Only mist an area which can be worked prior to gelation. B. A brush may be used to assist with coverage and removal of entrapped air. C. Apply a ber-reinforced Polylite Prole Tooling resin layer to approximate thickness of 3045 mils (0.761.14mm) accomplished in one or two passes.

G9


33540 Series

Technical Tips |
33542 Series

33541 Series

STEP 7ROLLOUT A. Remove all entrapped air with a brush or roller after each pass. Carefully inspect and remove air voids in laminate before proceeding to the next laminate application. Laminate applications must have a minimum thickness of 120 mils (3.05 mm) prior to gel and cure. B. Work out all entrapped air.

STEP 8CURE A. Allow the exotherm of each 120 mils (3.05 mm) laminate to subside before proceeding with subsequent applications. Failure to do so will decrease the working time of subsequent laminations. Because in-service requirements of tools vary, it may be necessary to apply multiple laminates to achieve the desired cross sectional thickness of the completed tool. B. Repeat Step 7, as needed, to achieve the required composite thickness. C. After each laminate application, trim excess glass from ange edge of the tool after partial cure is reached. The use of backup core reinforcements is not recommended.

STEP 9VACUUM CHANNELS A. Construct all vacuum chanels from suitable materials. B. Laminate vacuum chanels to designated locations throughout tool. After completion of cure pressure test using 35 psi of compressed air, repair as required.

STEP 10ADD BACKUP REINFORCEMENT STRUCTURE A. Cut and tailor a backup structure as required to maintain proper equipment. B. Scuff sand attachment points on the tool as required to ensure a proper t. C. Position structure on the tool and attach by spraying chop around each attachment point.

G10


33540 Series

Casting

33541 Series

PROCEDURE FOR MASS CASTING WITH ALUMINUM POWDER AND SHOT 1. Gel coat mold or plug with aluminum lled gel coat. Allow gel coat to cure to a very light tack. 2. Use a mixer like the type used to make cultured marble or concrete. Do not use blade type mixer used for tooling resins. Those mixers will not handle the high viscosity. 3. Add resin to mixer. 4. Add 0.4% 46559 promoter (if using 33540) to resins and mix 2 minutes or until completely mixed. 5. Add 0.75-1% 46750 peroxide initiator. Mix for 2 minutes or until completely mixed. 6. With mixer running, add aluminum shot. Weight of shot should be two times the weight of the resin used. Mix until shot is completely wet-out by resin. 7. With mixer running, add aluminum powder. Weight of powder should be two times the weight of the resin. Mix until powder is wet-out by resin. 8. Slowly add additional powder until no free resin is observed in the mix. Mix should have the consistency of a marble or concrete mix. Mix needs to be thick enough to prevent settling of the shot. Typical ratios are as follows: Resin 16-18% Aluminum Shot 38-40% Aluminum Powder 42-44% 9. Allow casting to cool down completely before removing from plug or mold

H1


33540 Series

Casting

33541 Series

PROCEDURE 1. Casting forms constructed and master secured, waxed and PVA applied 2. Gelcoat applied/cure 3. Surfaces brush coated with Prole (20%)/Aluminum powder (80%) mixture. Reichhold 46559 promoter 0.5% by weight. Superox 46750 1.5% by weight.. Gel time 5 minutes. 4. Cavity and at back section pours were made prior to curing item 3 above. Each pour consisted of the mixture as outlined above. a) Polylite 46559 promoter mixed into 33540 b) Superox 46750 initiator mixed into 33540 and 33541 c) Aluminum powder added to mix immediately followed by sphery shot 5. Geltime Cavity section Flat back section 6. Cavity section allowed to cure 24 hours prior to pouring of at back section 7. Drill and secure alignment bolts

TIME 2 hours 2 hours 0.25 hours

PHYSICAL PROPERTIES POLYLITE PROFILE CAST TOOLING Compressive strength: Materials Polylite Prole Tooling resin Polylite 46559 series promoter (for 33540) Aluminum powder Aluminum pellets Superox 46750 catalyst (for 33540 and 33541) Compressive strength @ 77F, psi. Compressive modulus, psi. x 105 Compressive strength @ 150F. psi. Compressive modulus, psi. x 105 Compressive strength @ 300F, psi. Compressive modulus, psi. x 105 Coefcient of Thermal Expansion, x 106/F 1 (-59300F) Thermal Conductivity (K) W/m *K

100 0.3 315 350 1.0 9,465 2.53 4,438 0.95 2577 0.71 9

0.1 hours 0.1 hours 0.2 hours

0.3 hours 0.3 hours

3.36 @ 165F 050 2.18

0.15 hours Heat Capacity (Cp), J/kg*K 1 Specic gravity gm/cc

H2


Packaging Non-returnable 55-gallon metal drums or 42,00044,000 lbs tank truck MaterIal Safety Data Read and understand the MATERIAL SAFETY DATA SHEET before using this product. Material Safety Data Sheets are available from your Reichhold representative. Make certain you obtain a copy of the Material Safety Data Sheet on this product. Users should request and understand such information from the suppliers of all materials prior to working with these materials. Reichhold Quality Policy Reichhold is committed to quality performance. We will satisfy the needs of the marketplace with innovative products which maximize value and performance, delivered to specication and on time. Storage To ensure maximum stability and maintain optimum resin properties, Dion, Hydrex and Polylite, resins should be stored in closed containers maintained below 75F (23.9C) and away from heat sources and sunlight. All storage should conform to local re and building codes. Drum stock should be stored away from all sources of ame or combustion. Inventory levels should be kept to a reasonable minimum with rst-in, rst-out stock rotation. Additional information on handling and storing unsaturated polyesters is available in Reichholds Application Bulletin, General Information of Storage and Handling Unsaturated Polyester Resins. For product information on other Reichhold resins, or Superox peroxide initiators, please contact your sales representative or your nearest Reichhold distributor. Disclaimer

Packaging / Safety / Quality / Storage

33540 Series

33541 Series

33542 Series

The recommendations made herein are based on our research and experience and that of others and are believed to be accurate. No guarantee is made to the accuracy or the results to be obtained from using any of the recommendations. Each manufacturer should make their own determination on the suitability of any recommendation for their own particular application and system. Nothing herein shall constitute or be construed as an express or implied warranty of any recommendation and the manufacturer assumes all risk associated with using any of the recommendations.

I1


33540 Series
Alabama Composites One Mobile 888-221-8133 Ashland Distribution Mobile 800-531-7106 Advanced Plastics Elberta 800-327-6136 Arkansas Composites One Van Buren 800-457-7017 Arizona Composites One Phoenix 800-522-2599 Ashland Distribution Chandler 888-877-0963 California Composites One W. Sacramento 800-654-5223 Composites One Madera 888-588-8520 Composites One Santa Fe Springs 800-237-0087 Ashland Distribution Carson 888-877-0963 Ashland Distribution Faireld 888-877-0963 Colorado George C. Brandt Centennial 303-584-0717 Florida Composites One Lakeland 800-344-0656 Composites One Miami 800-432-2752 Ashland Distribution Miami 800-531-7106 Ashland Distribution Tampa 800-531-7106 Fiberglass Coatings St. Petersburg 727-327-8117 Georgia Composites One Valdosta 800-458-5916 Composites One Lawrenceville 800-423-7874 Ashland Distribution Doraville 800-531-7106 Hawaii Fiberglass Hawaii Honolulu 808-847-3951 Illinois Composites One Woodstock 800-435-6138 Ashland Distribution Willow Springs 800-531-7106 Indiana Composites One Goshen 800-348-7503 Ashland Distribution Elkhart 800-531-7106 Kansas Ashland Distribution Kansas City 800-531-7106 Louisiana Ashland Distribution Baton Rouge 800-531-7106 Advanced Plastics Harahan 504-738-6035 Maine Composites One Rockland 207-594-7503 Massachusetts Ashland Distribution Tewksbury 800-531-7106 Michigan Ashland Distribution Warren 800-531-7106 Minnesota Composites One Lino Lakes 800-457-7011 Ashland Distribution Shakopee 800-531-7106 Missouri Composites One North Kansas City 800-457-7975 Ashland Distribution St. Louis 800-531-7106 New Jersey Composites One Millville 888-722-3371 North Carolina Composites One Smitheld 919-209-0840 Ohio Composites One Ashtabula 800-553-5483 Composites One Dayton 800-334-7498 Ashland Distribution Twinsburg 800-531-7106 Oklahoma Ashland Distribution Tulsa 800-531-7106 Oregon Ashland Distribution Portland 888-877-0963

Polylite Prole Distributors |

33541 Series

33542 Series
Ashland Distribution Houston 800-531-7106 Johnson Fiberglass South Houston 713-946-8444 Utah Composites One Salt Lake City 800-444-0156 Ashland Distribution Cleareld 888-877-0963 Virginia Ashland Distribution Roanoke 800-531-7106 Washington Composites One Vancouver 800-255-6006 Composites One Arlington 800-283-0809 Wisconsin Composites One De Pere 920-336-5898 Ashland Distribution Menasha 800-531-7106

Pennsylvania Composites One Monessen 800-736-0999 Ashland Distribution Morrisville 800-531-7106 Rhode Island Composites One Bristol 800-343-3030 Tennessee Composites One La Vergne 888-457-3401 Ashland Distribution Knoxville 800-531-7106 Advanced Plastics Nashville 800-321-0365 Texas Composites One Fort Worth 800-752-7839 Composites One Houston 800-451-8459 Ashland Distribution Garland 800-531-7106

I2

Corporate Headquarters

To receive information on the Polylite Prole Tooling System, Hydrex high-performance resins or other Reichhold products, call your local Reichhold representative.

Relchhold World Headquarters and Technology Center PO Box 13582 Research Triangle Park, NC 27709-3582 800.448.3482 (General Information) 800.431.1920 ext. 1 (Product Inquiries) www.Reichhold.com

I3