Molds finishes, surface

Gel coats are typicaHy used to provide a part with a finished surface directly from the mold. Various inserts, stiffeners, and mechanical attachments can be incorporated in the mol ding step, thereby further reducing secondary operations. Final edge trimming is accompHshed with a variety of tools such as... 

A special attribute of these processes is the abiHty to pre-position reinforcement, inserts, and core materials for stiffening ribs. Gel coatings can be apphed to the mold surface to eliminate post-mold finishing. Because both surfaces of the part are formed in a mold to close tolerances, accurate assemblies are possible, which is a requirement for many automotive or tmck body appHcations. 

Products in this process can have deep sections and relatively sharp comers. However RM flat, particularly large relatively uniform wall thickness surfaces are difficult if not impossible to produce. This process can be used to mold complex products that may require three or four split molds. Also, different finished surfaces are obtained. For example, the products surface finish is dictated by the inside surface of the mold. This makes it easy to obtain smooth as well as textured surfaces on the product. Raised or depressed letters, fluting, and other decorative inscriptions may also be molded. 

It should be recognized that surface finish can be more than just a cosmetic standard. It also affects product quality, mold or die cost, and delivery time of tools and/or products. The surface can be used not only to enhance clarity for the sake of appearance but to hide surface defects such as sink and parting marks. The Society of Plastics Engi-neers/Society of Plastics Industries standards range from a No. 1 mirror finish to a No. 6 grit blast finish. A mold finish comparison kit consisting of six hardened tool steel pieces and... 

Experience has shown that the finish on the part surface is a direct function of the mold finish, and that the mold finish is a direct function of the quality of the mold material. Excellent results have been obtained using high-quality, nickel-plated, tool steel molds and electroformed nickel shells. 

The single largest use for the phenol-formaldehyde resins is in adhesive applications for the production of plywood, chipboard, and particle board. The resin can comprise as much as one-third of the weight of the board, particularly of particle boards, which contributes to a total demand for phenolics in the U.S.A. of over half a million metric tonnes per year. They are also used as the matrix adhesives for the production of several types of grindstones. In combination with paper, woven cotton, glass fiber, etc., components, phenolics contribute to the production of engineering and decorative laminates in the form of rods, tubes, and sheets. The sheet products Arborite and Formica are familiar as the finished surfaces of furniture, bathroom, and kitchen counter tops and other areas where attractive patterns and water resistance are important characteristics. Molded products from phenolics are also important where heat or electrical resistance is required, such as saucepan and toaster handles, switches, and the printed circuit boards used in computers. Recent phenolics production in the U.S.A. has totaled over 500,000 metric tonnes per year, not including fillers [38]. 

Advantages of RTM are that the molded part has two finished surfaces, and the overall process may emit a lower level of styrene vapor if the polyester resin used contains styrene. The mold, unlike a compression or TP stamping mold, is completely closed to defined stops prior to final part formation/curing. This procedure provides a more reproducible part thickness and tends to minimize trimming and deflashing of the final part. 

Parts made of acetal homopolymer and copolymer are generally strong and tough, with a surface finish that is the mirror image of the mold surface. Acetal parts are generally ready for end-use or further assembling with httle or no post-mold finishing. 

Siiicones. Although silicones are used as both external and internal mold release agents, the primary application is as the active ingredient in external release agents. The silicone is in a solution or aqueous dispersion that is sprayed intermittently into the mold cavity between shots. A disadvantage of silicones as internal release agents is their possible interference with painting and contamination of finish surfaces. 

The process consists of a thin, unreinforced outer coat called a gel coat. The reinforcement (normally glass fibers) mixed with resin (usually polyester) is then applied by hand (lay-up) or via a spray gun (spray-up). When the desired amount of resin and reinforcement is in the mold, the air bubbles are pressed out with a roller. The part is then left to set up which, depending on the size of the part and the amount of resin, can take more than an hour. Consequently, many molds are used when higher production volumes are required. The molds themselves are made of plastic cast from a pattern. As such, they have a very short life and must be replaced frequently. Fortunately, they are inexpensive imfortunately, they are not capable of producing fine detail or close tolerances. Since the mold has only one side, only that side of the part has a finished surface the other side is very rough. The... 

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