The information given below is addressed to our customers and possible unprofessional persons interested, but it is unsuitable for anyone to make experiments at their home or anywhere else.
Without suitable processing conditions most of the materials to be used are harmful to health and there is danger of fire and explosion.
Suitable products and the way of their producibility are as follows:
1.Preparation of the primary pattern.
Based on the body-model received or prepared by ourselves we make, manually or mechanically, a model from wood, artificial wood or plastic material. Our new, CNC-controlled, 5-axle milling machine permits us to prepare quickly high-precision patterns even in the case of complicated forms.
2. Preparation of moulds to open technologies.
(e.g. manual laminating)
Our moulds are made upon our own design. Their materials are heat-curable reinforced synthetic resin composites having „sandwich” structure, and are completed with steel framework. The main point of the process is that, the multi-component, filled or fibreglass-reinforced special synthetic resin layers, which are curable at room temperature and suitable for the mould-production, will be applied manually to the primary pattern covered with special mould release agent, and after curing, but before the separation of the primary pattern from the mould, it will be reinforced by an adequate steel frame. The number of layers applied, the level of reinforcement and the rigidity of the steel frame may vary in function of the production technology applied, but they are always pre-calculated. In the mould prepared in such a way, you can produce a product, one side of which, namely the side in touch with the mould surface, will have a structure identical with that of the mould (external side), while the surface on the other (internal) side will be dependent on the pattern of the reinforcing material and on the manual skill of the worker.
3. Preparation of moulds to closed technologies.
Partly the process is identical with the former one, but the product to be prepared is precisely formed already in the first mould-half (let’s call it shell-mould) from an elastic material (e.g. from wax), taking good care to the desired thickness of the material. After that the first mould-half prepared this way will be considered primary pattern, and the second mould-half is made on this base in the same manner. This will be the core mould. After that, the two halves are taken to pieces, the model-material of the product is removed, and the resulting cavity between the two mould-halves will be the place of the product to be prepared. In the mould prepared this way, both the external and internal sides of the product will touch the mould surfaces, therefore their superficial structure will be identical with them. It is a further advantage that, the wall thickness of the product will have the desired measure even without any subsequent processing.
Our moulds are made of qualified materials, with careful observance of our own technology, and are intended for long-lasting use. That’s why in our case the number of pieces made by the same mould exceeds the average number in the profession.
4. Preparation of plastic master pattern.
In order to assure the security of the production, when the order or the expected number of a given product may reach a quantity of over 4-500 pieces, we prepare a plastic master pattern of the approved mould. This will enable us to prepare a second, third, etc. mould. Its material is fibreglass reinforced synthetic resin composite. Its design, structure and the method of preparation is the same as in the case of a laminating mould. Due to the fact that it is made from the mould, its external appearance is the same as that of the primary pattern, however, in contrast with the primary pattern, it can be stored without impairment for an unlimited time period, due to the nature of the composite.
Our product manufacturing technologies
1. Manual laminating
This is a traditional „open” technology. The point of the process is that, the liquid synthetic resin mixed with a catalyser is uniformly carried up manually, by means of a brush or an other instrument to the surface of the mould, which has previously been coated with a mould release agent, and subsequently the reinforcing material (e.g. fibreglass sheet) is laid in and impregnated by a brush, cylinder or other instrument. This procedure can be repeated several times in function of the desired wall thickness of the product. After curing the product is removed from the mould and cut to size.
This is an environment-friendly „closed” technology. The essential character of the process is that the calculated quantity of the reinforcing material of the product to be prepared is laid to the bottom mould-shell. After that the two mould-halves are closed. The quantity of the synthetic resin, that is conform to the useful cavity of the mould, is delivered into the work-cavity mechanically, under pressure, from a closed container through a pipeline. By this process we can produce high-precision elements with high reinforcing material content.
The process is the same as the previous one, but the pressure side is complemented with a vacuum unit. Before injection the cavity of the mould is placed under about 400 mbar regulated vacuum. Through this process we can produce also products combined with sandwich-core, which are free of any air-inclusion, and the result is the same as at the previous one.