MOLD RELEASE PRODUCTS: MOLD PREPARATION

Transcription

MOLD RELEASE PRODUCTS:
• Mold Release Agents
− Semi-Permanent
− Multiple Release Wax-Based
•
•
•
•
•
Mold Sealants
Cleaners
Compounds & Polishes
Additional Waxes
Supplementary Products
MOLD PREPARATION PROCEDURES
www.FinishKare.com
To Our Valued Customers:
Through the years, Finish Kare has promised
and delivered new products and new
procedures for the mold release industry. With
a heavy emphasis on R&D, we have been
able to continually improve upon old products
and create new products to keep up with the
changing Industry.
This new brochure is presented to you to
introduce new product concepts as well
as provide simplified and improved mold
preparation procedures. Both will help reduce
your time, labor and materials and ultimately
your production costs.
The brochure is divided into 2 sections; Section
1 highlights the key features of Finish
Kare’s products and their usage while Section
2 focuses on mold release procedures and
systems.
We would like to take this opportunity to thank
you, our customers, for supporting Finish Kare
over the years with your continuing business as
well as your feedback on our products (helping
us make them even better).
Please feel free to give us your comments
at any time and let us know if you have any
questions about our products or their usage
procedures.
TABLE OF CONTENTS
SECTION 1:
FINISH KARE’s Mold Release PRODUCTs
Non-Wax-Based Semi-Permanent Mold Release Agents . 3
Wax-Based Mold Release Agents . . . . . . . . . . . . . . . . . . . . 3
Mold Sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cleaners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Compounds and Polishes . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Additional Waxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Supplementary Products . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SECTION 2:
Using #1000P: Hi-low Paste Wax . . . . . . . . . . . . . . . . . . . 10
Using #135T: Semi-Permanent Polymer Release Agent . . 11
Glass & Stainless Steel Molds . . . . . . . . . . . . . . . . . . . . . . 12
Urethane & Elastomer Resins Molds . . . . . . . . . . . . . . . . 12
Resin Transfer Molds (RTM) used with Densified
Marble & Densified Granite . . . . . . . . . . . . . . . . . . . . . . . 13
Buffing & Polishing of Mold . . . . . . . . . . . . . . . . . . . . . . . . 14
Storing Molds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Rejuvenation of Older Molds . . . . . . . . . . . . . . . . . . . . . . 15
“Anti-Static” Release System . . . . . . . . . . . . . . . . . . . . . . . 15
Preventative Mold Maintenance . . . . . . . . . . . . . . . . . . . . 16
Sincerely,
Jitu Jhaveri
Jitu “JJ” Jhaveri, President
FINISH KARE PRODUCTS, Inc.
––
SECTION 1:
Mold Release PRODUCTS
This section provides information for the products used in the three key steps in the
preparation of molds:
– MOLD RELEASE AGENTS
– MOLD SEALANTS
– CLEANERS, COMPOUNDS and POLISHES
WAX-BASED MOLD RELEASE AGENTS: #1000 Series Mold Release Waxes are
formulated with the help of today’s modern chemistry. Thus, they work in extreme conditions of acceleratedexothermic, high-temperature conditions (HIGH) and low-to-ambient-temperature conditions (LOW).
HI-TEMP and HI-LOW 1000 Waxes contain a blend of synthetic waxes that reduce the quality fluctuations
that are found in natural organic waxes such as carnauba. Synthetic waxes that FK uses in its mold release
waxes have the high melting points and the proper hardness to get the desired film properties on the mold
surfaces. The resulting film has a high gloss and intensive wear-resistance under the high or low temperature
molding conditions. This assures an easy release.
PLEASE NOTE: EACH OF THE 1000 SERIES WAXES CONTAIN DIFFERENT BLENDS OF SYNTHETIC
WAXES AND SOLVENT MIXTURES TO GET THE DESIRED AND UNIQUE PROPERTIES.
#1000P: HI-LOW PASTE WAX
• Contains a blend of synthetic waxes
and is one of FK’s premium mold
release waxes.
• Proper application of this wax will result
in a film that has high gloss, intensive
wear and great resistance to heat and
water. Thus, it is recommended for new
and reconditioned molds.
resistant resins for effective multiple releases of plastic parts
through numerous cycles.
• Good for up to 230º F or 110º C.
• Buttery texture provides easy on/off applications – sets up
faster and harder and assures quick, clean releases without
wax buildup or transfer.
• Recommended for the effective release of any FRP or
cultured marble parts, polyesters, polyurethane, etc....
#1000L: HI-LOW LIQUID WAX
• Specially designed for use between multiple
releases to relieve the wax build up and
reduce surface tension in molds.
• Helps to prolong the life of multiple
cycle releases.
• Solvents in the product liquefy the mold
release waxes and form an even coat on
the mold for easy de-molding.
#888: Max Mold Release Paste
Wax
• Similar in hardness to #1000P. It is
yellow in color and has a peculiar,
turpentine smell.
• Comparable to Meguiar’s # 8. Our
extensive testing shows that you get
equivalent or better release with
# 888 than the comparable Meguiar’s
product.
• This is one of our newer products—
sample requests welcome.
#1165: HI-TEMP STABILITY EXTRA HARD PREMIUM WAX
• As the name implies, designed to withstand higher temperatures
and is harder than other waxes.
USAGE: Higher temperature exothermic reactions.
#333MR: BLUE PASTE RELEASE WAX
• True High Gloss Paste Wax
– withstands high-temperature
exothermic reactions of resins and
does multiple releases easily.
• Contains carnauba wax, synthetic
waxes and high-temperature
#1006: MOLD RELEASE PASTE WAX
(PRE RELEASE DETERRENT)
• Specially designed to reduce the slip factor, which under
some situations might allude to pre-release.
• In the event “pre-release” occurs on corners, wells and radiuses
due to excessive exothermic heat generated by mass chopping
over these areas due to repeated passes, apply #1006 as the last
––
Mo ld R e lease PRODUC T S
WAX-BASED MOLD RELEASE AGENTS:
coat or last two coats over the application of #1000P prior to gel
coat and lay up.
#1004-23: BRUSH GEL COAT RELEASE PASTE WAX
• Formulated so as to be brushed over gel coat before the final
wax coat is applied without worrying about fish eye.
• Recommended to be applied to any mold surface, whole or
partial, where brushing the gel coat on the mold is required.
Note: a camel hair soft brush is recommended for brushing gel
coat.
• Can be used over #1000P as the final coat or used by itself
when gel coating.
APPLICATION TIP: Cutting the tip of the brush helps to get even
distribution – lay your brush flat while applying. Do not use the
tip of the brush because it may remove the release film and
causing spot bonding. Apply thin coats; making sure it is dry
before wiping.
#1000L-28: SPRAYABLE HEAVY-DUTY MOLD
RELEASE WAX
• Heavy-duty cousin of FK’s sprayable mold release agent
#332. Contains the same high-melt synthetic blend waxes
incorporated into #1000P (Hi-Low Paste Wax) and #1000L
(Hi-Low Liquid Wax) but the solvent systems have been
changed to reduce viscosity and make the product sprayable.
• Field tested and fully embraced by all users because it gets
the
job done – especially for larger molds, panels and other
large
jobs that require excessive labor for application of paste or
liquid waxes.
• Very easy application – just spray on, allow it to dry and
then wipe lightly – quick and easy. Cuts your labor costs and
increases your productivity.
NON-WAX-BASED SEMI-PERMANENT RELEASE AGENTS:
#135T: POLYMER BASED RELEASE AGENT
A Polymer-based release agent which has high heat stability. It’s polymers provide multiple releases
and protection from high heat generated from accelerated exothermic reactions.
It is specially designed for:
• Accelerated Exothermic Resins up to 400º F or 204º C
• Multiple Releases
• Compression Molding
• Vacuum Bagging
• Resin Transfer Molding (RTM)
NOTE: For best results, use terry cloth or Turkish towels when applying #135T. Apply in a circular
motion to mold by overlapping previous area. Work product in thoroughly over the mold creating a
thin even coat. Check for uniform coverage. Allow it to dry. Reapply as directed.
#135T may be sprayed. When applying, if sprayed, we suggest wiping it lightly over sprayed film for uniform coverage.
#135ER: URATHANE RELEASE
It is recommended for the following types of urethane moldings:
1. Elastomer Urethane
2. Polyisocynate Component A
3. Hydro-Resin Component B
4. Urethane Foam
5. Isocynate Component A (Diphenylmethone)
6. Poly Component B (Polypreponal Glycol)
Note: For #135 ER, follow the same guidelines as #135T.
––
CLEANERS: These are solvent cleaners to clean and remove any foreign matter from
the mold surface to get it ready to seal them before applying release agents.
#69: MOLD CLEANER & STRIPPER
#80: LIQUID MOLD CLEANER
• S ame usage as #135-80, but # 80 is a
milder, cleaner version that contains
no toluene or polymers.
• Specially formulated for cleaning
Elastomer Resins (ER).
• Contains special surfactants that do
not react with the resin that other
cleaners might.
• S pecially formulated for the
Reinforced Fiberglass and Plastic
(FRP) Industry to clean molds and
relieve the problems of wax build-up
& over-spray from mold surfaces.
• Important mold release components
of Hi-Low Temp 1000 series waxes
are specially blended in this product
to liquefy and remove most waxes
from the molds.
• Can also be used as an inter-phase item for the wax system
for prolonged releases and as a cleaner for sharper molds
and parts.
• Please note #69 does not relieve Styrene burns.
#69AS: ANTI-STAT MOLD CLEANER & STRIPPER
• Same as above, but contains anti-static agent
#135-80: POLYMER MOLD CLEANER AND WAX REMOVER
• Solvent-based mold cleaner for
removing wax.
• Contains toluene and fortified with
polymers.
• A much stronger cleaner than #69 that
can be used for the clean-up of all types
of molds prior to applying porosity
sealing agents and mold release agents
– wax-based or otherwise.
• Apply at least 2 coats of #135-80 for
proper cleaning of molds and assured
releases.
MOLD SEALANT: Molds
APPLICATION PROCEDURE for FINISH KARE CLEANERS:
1. Apply #69, #135-80 or #80 over a controlled area by
saturating a terry cotton cloth with the product.
2. Agitate and wipe wet. Wiping wet allows to pickup
foreign matter which have been dissolved or
dislodged by agitation.
3. Continue this procedure until the entire mold has
been cleaned.
4. Reapply a light, even coat of #69, #135-80 or #80 to
assure a non-waxy, greaseless surface and wipe.
5. If there is heavy build-up of wax, repeat the process.
#86: SEAL KOTE
are made up of FRP, aluminum, glass,
metals, gel coats and various other
materials which are porous so they need
to be properly sealed to prevent resins
being lodged in the mold surface and part
being stuck.
• A polymer solution
designed for efficient
“sealing of porosity” in new
and rejuvenated molds.
• Aids and assists in the
release of waxes to assure a
clean and easy demolding.
––
COMPOUNDS and POLISHES: Mold surfaces get damaged and
warped due to wear and tear of constant use and heat generated during exothermic reactions
from the resins. So, to get the good quality products and to extend the life of molds they need
to be repaired periodically to make them working like new and get more usage out of them.
Please note the products are listed in order of their aggressiveness, such as # 103 is more
aggressive than # 440-5.
#103: EXTRA HEAVY DUTY CLEANER
• FK’s premium cleaner that incorporates
glazing and spreading agents.
• Cleans deeper without any heavy
abrasive action.
• E asily relieves buffer swirls, paint and
gel burns; Smoothens and removes fine
scratches and blemishes.
• Assures a deeper and cleaner finish on
mold for sharper parts.
• Recommended for rubbing out slight
imperfections in the mold or finished
parts and for removal of oxidation and/or
discoloration of older parts.
#600: WHITE FINE RUBBING
COMPOUND (PASTE)
• Fast cutting compound that can be
applied by hand or machine.
• Recommended for rubbing out fine mold
imperfections and smoothening of orange
peel, fine or minor scratches and overspray.
• Removes and blends or does touch up of
mold surfaces when removal of foreign
matter is essential.
• Can also be used in heavy-duty work.
#440-5: POLISHING COMPOUND
• Specially formulated for removal of wet
or dry sanding marks, imperfections and
other mild defects without scouring the
gel coat.
• A fast cutting compound formulated with
fine abrasives and silicates to remove fine
to medium scratches and blemishes.
• Can be used to all gel coated surfaces as
well as other mold materials.
––
#923: MICRO POLISHING COMPOUND
• A fine micro compound formulated
to remove sandpaper marks and
imperfections quickly and easily while
leaving a high gloss and minimizing swirl
problems.
• Easily removes 1500 grit sand marks with
a 100% wool cutting pad or 2000 grit or
finer with an aggressive foam pad.
• Can be applied to all painted or gel coat
surfaces.
#330: MINI BUFF
• Made with a heavy wax base.
• Fine polishing compound used for the
final machine polishing and dressing of
molds before sealing and waxing.
• Improves clarity and luster.
• E xcellent for older parts where light
buffing may be required.
ADDITIONAL WAXES:
#68: EDGE WAX
• Formulated specifically for the fiberglass, marble industry
where a flange- or edge-wax is required to assist in the
prompt and easy release of the part.
• Edge Wax is a semi-paste and it incorporates synthetic
waxes into a system that forms a film that is virtually
unbendable when applied as per following instructions:
1. Apply three consecutive coats of #68 Edge Wax, allowing
each to dry before applying the next.
2. Apply 2nd and 3rd coats to all flanges, corners, edges
and areas where a gloss is not required. This builds up
a wax surface that will produce multiple releases and
should only require periodic application unless the area is
marred when pulling the part.
3. Reapply the Edge Wax to affected areas and a thin coat
all over to get an even film.
#332: HAND OR SPRAY INTERPHASE & RELEASE WAX
• Synthetic, polymer-resin-based, low-viscosity sealant that can
be sprayed- or wiped-onto the prepared mold.
• Highly recommended as a spray base mold release wax for
all non-skid areas.
Apply in the following manner:
#PB-1: TRAFFIC WAX
• Blend of synthetic waxes designed to seal porous surfaces
where resins and gels might accumulate.
• Can be mopped- or wiped-on –reducing clean up time and
increasing efficiency in production
• Eliminates fire hazard by removing the use of paper.
• One gallon of PB-1 will cover approximately 150-200 square
feet on porous surface and up to 400 square feet on smooth
non-porous surface.
• Recommend using three applications; Allow each coat to dry
prior to applying the next coat – assuring proper coverage.
#626: POLYMER HAT WAX
• Formulated for onyx & marble manufacturers
• Blend of synthetic waxes, polymers and resins for high-heat
stability and multiple releases.
• Brush or wipe on three consecutive coats of #626, one coat at
a time allowing each coat to dry before reapplying second and
third coat to all hats, flanges, corners, edges and areas where a
gloss is not required. Do not wipe. This builds a wax surface that
will produce multiple releases and should require only periodic
application unless area is marred when pulling a part. In this case,
reapply #626 Polymer Hat Wax to affected area.
1. For High Shine: Spray on, allow it to dry and wipe off.
2. For Dull Finish: Spray on, allow it to dry, wipe off surplus
from only outside surfaces.
3. On non-skid area, just apply but do not wipe.
PLEASE NOTE: THIS PRODUCT SHOULD ONLY BE USED
IN THIS MANNER AFTER AT LEAST ONE DEMOLDING
PROCESS HAS BEEN DONE WITH USE OF FK’S PASTE WAX.
#604-B: MOLD SEALER & RELEASE AGENT
• Formulated exclusively for the FRP, cultured marble and
onyx manufacturers.
• Semi-viscous paste wax that may be brushed- or wiped-on.
• White in color so that it will not discolor.
• Also effective in release hats, flanges and back splashes.
Use as follows: Apply three consecutive coats of #604-B with a
brush, cloth or sponge, one coat at a time. Allow each coat to
dry before applying second and third coats to all flanges, hats
and back splashes where gloss is not required. This builds up
a wax surface that will produce multiple releases and should
require only periodic application unless area is marred when
demolding. In this case, reapply #604-B to the affected area(s).
––
NOTE: On some molds Polymer Hat Wax acts as
a transfer wax, whereby it will be removed with
the first, second or third pull and will leave a bright
shine on the mold. This shows that the polymer
resin has fused to the mold and it will allow several
additional releases without reapplication. As the
mold dulls down or the part pulls hard, reapply and
continue cycle.
IMPORTANT: When changing products, or
periodically as a mold maintenance program,
you need to wipe the molds down. This reduces
resin transfer, wax build-up, hazing, etc... FK has
developed a special polymer mold cleaner, #13580 for this purpose. It will deter build-up of wax
and styrene resin and will assure longer mold use
with continuous releases. #135-80, Polymer Mold
Cleaner inclusively forms a film on the mold that
deters build-up, and extends the use of #626 by
giving additional releases, thus reducing costs.
ADDITIONAL WAXES (cont.):
#331-21: STORAGE WAX
• Incorporates a blend of polyethylene resins, polymers and
sun screening agents to form a protective barrier against
exposure, inclement weather, heat, and ultraviolet solar rays.
• A protective coating without the extreme and difficult problems
of removal that most products of this nature represent.
• Recommend use of either pressurized or siphon spray
gun as an applicator. When spraying, do not to exceed gun
pressure greater than 40 PSI. Adjust fan to desired width
over a pre-cleaned surface. Spray one coat; allow it to
dry. Cross spray, allow to dry. Spray flow coat to desired
thickness and or coverage.
REMOVAL: On molds that have been exposed to weather
conditions and have become coated with dirt, dust or grit, hose off
entire mold to remove debris prior to washing and wiping. Wipe
with cloth or wash with simple soap solution under agitation. In
extreme cases, wipe down with our product #69 liquid release
and stripper, re-wax, to remove. Reapply one or two coats of wax
or release agent and then place back into production.
SUPPLEMENTARY PRODUCTS:
PVA BY FK
Three products available:
• #65 PVA Blue/64 PVA Clear: for fine film work
• #664 PVA Satin Finish: for onyx resin surfaces, for marble
industries w/ or w/o gel coats.
• #67 PVA Green: for heavy duty work.
NOTE: Those of you who are in tooling or who are making your
own molds or own prototypes with plaster, clay etc... should
consider PV-6 that gives immediate results without the problems.
It contains no waxes or silicone. This product is directed to
tooling all masters and to breaking in new molds.
Blend of resins and plasticizers that give a spray film its elasticity
and complete coverage unequaled in the industry. Consecutive
coats create desired soft tone or dullness.
PVA APPLICATION:
1. Set spray pressure not to exceed 25 PSI.
2. Spray a fog coat and allow film to dry to firm tack.
3. Cross-spray to get the complete coverage and allow film to
dry to firm tack.
4. Spray a flow coat of 4 mil thickness.
Note: Make sure final coat is completely dry prior to spraying
gel coat or casting.
APPLICATION:
1. As in PVA, spraying is preferred, although brush application can
be used. When spraying, use 20-30 PSI.
2. Apply a first coat, known as Fog Coat. Allow it to cure 1015-minutes.
3. Then apply a 2nd coat, a Fill Coat (a bit heavier).
4. Finally apply a 3rd coat, Flow Coat, assuring adequate
coverage and an even and a continuous film (3 to 4
mils thickness is required). Allow the last coat to cure
thoroughly before laminating or casting. Once solvent odor
has disappeared, mold is ready for laminating or casting.
If brushing is preferred, use a soft bristle brush. Brush as you
would do in varnish, shellac or lacquer. Use a well-filled brush
with light, fast strokes and work from wet to dry areas. A fairly
heavy first coat is suggested for proper coating followed by
lighter applications to fill in pinholes or build up thin spots.
#PV-6: SPRAY OR BRUSH RELEASE AGENT,
THE TOOL MAKER’S FRIEND
• Film forming agent that serves as a sealer and release
agent in liquid form. Gives a more-immediate dry and
polymerization of the release film.
• PV-6 in lieu of PVA may be applied when the relative humidity
is high and the ambient temperature is low. Unlike PVA which
will separate and fish-eye or dissolve when sprayed over
moisture, PV-6 will bond to and develop a release film in spite
of the moisture contents of any substrate or surface. Can be
sprayed over plaster, clay, wood varnish and shellac surfaces
that may contain moisture of various types.
TO REMOVE COATING: If the film is of proper thickness, it can be
blown off with air nozzle. If not, remove it with acetone. Also
clean spray gun with acetone.
#641-C: SURFACING AGENT
• A no styrene intermix surfacing agent – greatly reduced
costs.
• Can be sprayed or brushed on.
• Greatly reduces pin holes, resin tack and air bubbles.
Leaves a non-porous surface.
• Add 1-2% to resin.
––
SECTION 2:
General procedure for preparation of molds can be described in three easy procedural steps:
1. Cleaning the mold surface
2. Sealing porosity of the mold surface
3. Application of mold release agents
In the case of old molds, one has to rejuvenate the mold surface or make the mold surface
like new by sanding and applying compounds & polishes depending on the conditions of the
mold prior to following the above outlined procedure.
Various types of mold materials are used depending on what types of products are being
cast. In general molds are made from:
• Aluminum
• Stainless Steel
• Tempered Glass
• Densified Marble
• Densified Granite
• Urethane, which includes, Elastomer Urethane, Polyisocynate Component A, Hydro
Resin Component B, Urethane Foam, Isocynate Component A (Diphenylmethone),
Polyol Component B, etc…
• Epoxy
• Plaster, etc…
Some of these mold materials require special attention and preparation. Thus, on the
following pages, we provide the necessary information about how to handle various types
of molds as well as specific procedures and the materials required to work with each of the
mold materials listed above.
Please feel free to copy any of the following procedural pages for shop personnel.
Hang in the work area for easy reference and better demolding.
––
MOLD PREPARATION USING #1000P:
HI-LOW PASTE WAX
Finish Kare (FK) recommends the following procedures for new molds. The same procedure is also used in its
entirety when old molds are sanded, compounded and polished to remove scratches and blemishes after molds are
damaged due to their use.
CLEANING:
STEP 1: Clean the new mold by applying one (1) coat of #135-80*: Mold
Cleaner & Wax Remover. Agitate and wipe while wet. This will help remove
the contaminants and debris that have been dislodged and have become
loose from the mold.
STEP 2: Then clean the mold by applying one more coat of #135-80 as done
in Step 1. Let it dry thoroughly and wipe. In some cases a 3rd application
may be required. Just make sure it looks and feels clean by running your
finger over the edges of the mold. (Please note: Never touch the inside of
the mold surface with your fingers because it will leave oils from your fingers
tips on the mold surface and may hinder sealant bonding.)
SEALING POROSITY:
STEP 3: Now apply a coat of #86: Seal Kote. Allow it to dry thoroughly
for about 30-40 minutes, and lightly wipe. (Please note: Drying time may
depend on weather conditions.)
STEP 4: Reapply another coat of #86 and allow it to dry, wipe lightly and let
it set for an about 60 minutes. This will allow the polymer to set and bond
to the mold surface and will leave a nice intact, uniform film. Wipe the mold
dry with a soft, clean cloth. It is best to use terry cloth or cotton towels.
APPLYING MOLD RELEASE AGENT:
STEP 5: Apply #1000P: Hi-Low Mold Release Wax in five (5) separate
applications. Make sure that each coat is dry prior to wiping. Please
crisscross each application to assure complete coverage. Apply wax in a
circular motion to work the wax in.
STEP 6: Allow 30 minutes to set after the final wipe then re-wipe. Pour the
first part and release it.
STEP 7: After releasing the part, gently wipe the mold, then apply one more
coat of wax and release one more part.
At this point, Mold is cured to the point that Multiple Releases Are Possible.
STEP 8: When a part gets a little hard to pull, apply one coat of #1000L:
Hi-Low Liquid Wax, let it dry and wipe lightly. Run more parts and apply
#1000L as needed. Use of #1000L helps in preventing wax buildup and thus
helps in multiple releases.
NOTE: While tooling Gel Coat or Green
molds, use at least 4 applications of #86
per the instructions to the left. Please allow
ample time for each coat to dry prior to
wiping it and reapplying.
PRECAUTIONS:
1. Make sure each coat of wax is dry prior
to wiping it.
2. Allow a minimum of 30 minutes to
dry each coat of wax. In extreme
cold temperatures and high humidity
or inclement weather, please allow
additional time (45-60 minutes) prior
to wiping. Before wiping make sure wax
coating is dry.
3. For best results, use Turkish-type cotton
towel to wipe off.
4. In the event mold has become scarred or
shows any visible blemishes or scratches,
re-work this area (or preferably the entire
mold) before pouring any new part.
NOTE: Some mold manufactures recommend
the spraying of one coat of PVA over wax
for several releases when breaking in a
new mold. We recommend use of FK’s
PV‑6: Mold Release Film mainly for tooling
application. PV‑6 is a solvent based film
former, it dries quickly and may be used over
plaster, etc... where moisture may be present.
Once the mold is cured, this procedure may
be eliminated and multiple releases wax
system may be put into practice.
* #135-80 is one of our newer cleaners. In the past
we used to recommend use of #69, which is still
available. #135-80 is little expensive compared to
#69; however, it is a much better cleaner and will
accomplish your cleaning much more quickly and
efficiently; thus resulting in overall cost savings.
#135-80 contains toluene as one of the cleaning
component so it may not be suitable in certain
cleaning conditions. Under these circumstances
#80 will do a good job for you.
FINISH KARE PRODUCTS, INC.
T: 626-443-8983 • F: 626-443-0288
www.FinishKare.com
– 10 –
MOLD PREPARATION USING #135T:
SEMI-PERMANENT POLYMER RELEASE AGENT
This procedure may be used on New Molds, Reconditioned molds, tooling plugs or Release System Change Over.
Some of these molds may have been sanded, compounded or polished.
CLEANING:
STEP 1: Pre-clean the mold with #135-80: Polymer Cleaner & Wax
Remover. Soak cloth with the product, apply it to surface, agitate
and wipe while wet. Clean small areas at a time and continue in this
manner and treat the entire mold.
STEP 2: Apply a 2nd thin and even coat of #135-80. Allow to dry
and wipe gently. If there is a heavy wax build up, repeat the cleaning
with #135-80 until you are fully-satisfied and the mold is clean.
SEALING POROSITY:
STEP 3: For sealing porosity and to assure a better release, apply 4
coats of #86: Seal Kote. Please allow each coat to dry thoroughly
before applying the next coat. Wipe lightly between each coat so
that you are leveling the material and not removing it.
APPLYING THE MOLD RELEASE AGENT:
STEP 4: Apply 4 consecutive coats of #135T: Semi-permanent
Polymer Release Agent and allow each coat to dry a minimum of 10
minutes. DO NOT WIPE.
#135T may be sprayed. If sprayed, wipe it lightly over the sprayed film
to get uniform coverage.
For Best Results: Use Turkish cotton or terry cloth towels when
applying #135T. Apply it in a circular motion overlapping previous
areas. Work product thoroughly over the mold creating a thin even
coat. Check for uniform coverage.
STEP 5: Apply an extra coat of #135T on all radiuses, corners and
wells. Allow it to dry for 15 minutes and then wipe lightly to get an
even coat.
STEP 6: Laminate or cast your first part.
STEP 7: Release the part. After this first release, reapply one more
coat of #135T. Continue with multiple releases and reapply #135T,
as needed when the pull becomes a little hard.
NOTE: We cannot stress enough the importance of
the mold being clean prior to applying the release
coat. In addition, make sure each coat, including the
final coat, is dry and cured prior to casting or wiping.
We recommend that each coat of wax or #135T be
thin so it will dry better.
T: 626-443-8983 • F: 626-443-0288
www.FinishKare.com
– 11 –
PROCEDURE FOR GLASS &
STAINLESS STEEL MOLDS
ALL GLASS MOLDS SHOULD BE MADE UP OF TEMPERED MATERIAL.
CLEANING:
STEP 1: Wash mold with soap & water. Then, apply one coat of #135-80: Mold Cleaner and Wax Remover.
Spread, agitate and wipe wet. Make sure that mold is clean. Wiping wet allows one to pick-up loose debris and
contaminants.
STEP 2: Apply one more coat of #135-80, agitate and wipe wet. Reapply #135-80 and allow it to dry thoroughly,
wipe off film. At this point the surface should be friction free, bright and shiny.
SEALING POROSITY:
STEP 3: Apply 4 consecutive coats of #68: Edge Wax. Spread the wax evenly over the surface of the mold. Allow
each coat to haze before buffing it into the mold using a 100% wool cutting pad until the wax disappears and
creates a high gloss surface.
STEP 4: Apply 5 consecutive coats of #1000P: Hi-Low Paste Wax. Allow each coat to dry thoroughly before
wiping it gently.
STEP 5: Pour part and proceed.
PROCEDURE FOR URETHANE &
ELASTOMER RESINS MOLDS
CLEANING:
STEP 1: Wash the mold with #80: Cleaner & Wax Remover, agitate and wipe wet. Apply a 2nd coat, let it dry. DO
NOT WIPE.
STEP 2: Apply 2 consecutive coats of #135ER and allow each to dry for about 20 minutes.
DO NOT WIPE.
STEP 3: Now apply 4 consecutive coats of #135ER and let them dry for about 20 minutes between each coat. Do
not wipe other coats, but wipe only the last coat.
STEP 4: Allow the last coat to cure for about 45 minutes before pouring matrix. Release the part and apply one
more coat of #135ER. Now the mold is ready for multiple releases.
STEP 5: Reapply #135ER as needed when the part becomes a little hard to pull.
T: 626-443-8983 • F: 626-443-0288
www.FinishKare.com
– 12 –
PROCEDURE FOR RESIN TRANSFER MOLDS (RTM)
USED WITH DENSIFIED MARBLE & DENSIFIED GRANITE
The following procedures and products are recommended to assure you of proper mold preparation to get clean
multiple releases when making densified products using the RTM system.
1. Cleaner– #135-80: Mold Cleaner & Wax Remover
2. Porosity Sealant– #86: Seal Kote
3. Mold Release Agent– #135T: Semi-permanent Polymer Release Agent.
NOTE: THIS PROCESS USED ONLY ONCE ON THE NEW MOLD WILL BE SUFFICIENT TO BREAK IT IN.
ON REPAIRED SURFACES PLEASE FOLLOW THE PROCEDURE LISTED BELOW:
CLEANING:
STEP 1: Saturate the cotton cloth with FK’S #135-80 and apply it quite wet and
agitate thoroughly. Work a small convenient area at a time, wipe while wet.
Continue to clean the entire mold in this manner.
STEP 2: Reapply #135-80 in a light even film while working the product well
over all surfaces until a light, waxy film appears. Allow it to dry, wipe with
a clean cloth. #135-80 acts as a cleaning and stripping agent.
SEALING POROSITY:
STEP 3: Apply #86: Seal Kote over the entire mold by working down to a
light, even and transparent film. Allow it to dry and set for 30 minutes. DO
NOT WIPE.
STEP 4: Apply a 2nd coat of #86 in the same manner; once again allow it to
dry. Do not wipe.
STEP 5: Now apply a 3rd coat of #86 in the same manner, but, after letting
it dry, wipe lightly to get an even film.
STEP 6: Apply #135: Semi-permanent Polymer Release Agent in a light,
even film over #86. Allow it to dry for 30 minutes and wipe lightly to get a
nice gloss.
STEP 7: Apply one more coat of #135T to assure that all the areas, such
as radiuses, corners, and wells are completely covered. The little extra
here and there will provide extra insurance for easy de-molding. Let this
last coat of #135 dry for at least one hour, wipe it lightly with a clean soft
cotton cloth to a nice glossy finish. Let it set for additional 15 minutes
and place the mold into production. This will effectively start the multiple
release cycle.
When parts show surface tension upon demolding and the release is
getting harder, reapply a coat of #135T in the same manner.
CAUTION:
1. This entire procedure needs only to
be repeated from step 1 if damaged
or affected area(s) are repaired by
sanding, compounding & polishing. The
repair process will strip the mold of all
waxes, sealant and mold release agents.
2. Periodically the seal and the mold
release agent film will degrade through
the sealer base depending on the
amount of granite used and vibrations
in the mold. This will show up when
you see spot sticking and some areas
are getting harder to release. When
you observe this, repeat the mold
prep procedure from the beginning to
assure proper mold preparation and
easy demolding.
3. An extra coat of #86 on areas
showing abrasion will assure additional
demolding cycles.
T: 626-443-8983 • F: 626-443-0288
www.FinishKare.com
– 13 –
PROCEDURES FOR BUFFING &
POLISHING OF MOLD
STEP 1: After sanding, buff the entire mold with FK’S #923 or #440-5. Use of
a wool cutting pad is recommended. FK’s #440-5 is more aggressive than #923.
If the mold is not really bad, FK’s #923 may be used for finer scratches and
blemishes and #440-5 may be used for deeper scratches without sanding.
STEP 2: Finish buffing entire mold with FK’s #330: Buff Wax. Use of a 100%
lamb’s soft wool polishing pad is recommended.
CLEANING:
STEP 3: Apply FK’s #135-80: Polymer Mold Cleaner and Wax Remover. Spread,
agitate and wipe while wet. For excessive wax buildup or residue, reapply
#135-80, allow it to dwell for penetration, then agitate and wipe. Sometimes, 3
applications of #135-80 may be necessary.
SEALING POROSITY:
STEP 4: Apply one coat of #86: Seal Kote. Allow it to dry 30-45 minutes and
wipe lightly.
STEP 5: Reapply another coat of #86, allow it to dry thoroughly and wipe
gently. Let it sit for about 60 minutes. This will allow the polymers to set and
bond to the entire mold. Then, wipe it lightly with a clean soft cloth.
NOTE: On tooling Gel Coat or Green Molds, FK recommends the use of at least 4 coats
of #86 while following the above instructions. Give ample time for each coat to dry prior
to wiping and reapplying.
STEP 6: Apply one of FK’s Mold Release Waxes (#104: Hi-Temp Release Wax,
#1000P: Hi-Low, #1165: Hi-Low Premium Wax or #333MR: Mold Release
Wax) in 5 separate applications. Wipe lightly after each coat and wait at least 30
minutes between each coat.
STEP 7: After applying the final coat of wax, wipe, allow 30 minutes to set, and
re-wipe. Pour the first part and release it.
STEP 8: Reapply one more coat of wax, pour part and release it. Now the mold
is ready for multiple releases, so proceed as in multiple cycles.
T: 626-443-8983 • F: 626-443-0288
www.FinishKare.com
– 14 –
PROCEDURE FOR STORING MOLDS
When pulling molds for storage, FK recommends use of #331-21: Storage Wax. It offers
protection during the storage period.
To place mold back into service, wash the mold with soap and water and wipe.
Then, follow the procedures outlined for New Molds or for Rejuvenating Old molds.
REJUVENATION OF OLDER MOLDS
Any scar, imperfection or scratch that remains after sanding and polishing will carry through as an
unsightly blotch and will mar the appearance of the finished part. Thus, sanding should be done
meticulously and in sequence of finer grits. You should finish the final sanding preferably with 1200
grit or better sand paper. To aid in detecting scratches during the repair process, occasionally
wipe-down the area with a 50:50 mixture of IPA (Isopropyl alcohol) and water. The alcohol
solution helps to remove any wax or fillers that may be hiding the finer scratches and blemishes.
This way, you can see the true finish of the mold surface.
FK recommends use of #780: Sand Lube* for wet sanding. We recommend to start off with 600
grit sand paper for wet or dry sanding using a rubber block. For wet sanding, wet out the sand
paper using a solution made with FK’s #780. Use a rubber squeegee to keep the mold dry. Finish
sanding with 1200 grit sand paper.
* Add 2oz. of #780 to ½ gallon of water.
“ANTI-STATIC” RELEASE SYSTEM
FK has three main products with anti-static properties:
1. #69 AS: Anti-static Stripper and Wax Remover
2. #1000L AS: Anti-static Hi-Low Liquid Wax
3. #1000L-28 AS: Anti-Static Spray Base Release Wax
Benefits of “Anti-Static” products:
1. Allows you to blow off dust from molds instead of wiping, thus saves time.
2. No tracking or clinging.
3. Definite neutralization of static charge.
4. Assured positive charge on molded parts resulting in cleaner, dust-free parts.
Use of #69AS in cleaning molds will eliminate dust and particle attraction to molds due to build up of static
electricity. It will zap the charge when applied after buffing or polishing.
T: 626-443-8983 • F: 626-443-0288
www.FinishKare.com
– 15 –
PREVENTATIVE MOLD MAINTENANCE
Annually, a great deal of production time is lost due to wax buildup,
surface tension and dullness in particularly tight areas over the mold.
Subsequently, crazing occurs and eventually parts are lost and there is a
need for mold repair and rejuvenation.
FK recommends using:
1. #69: Liquid Release & Stripper or #80 or
#135-80, Mold Cleaner & Wax Remover
2. #1000P: Hi-Low Paste Wax and
3. #1000L: Hi-Low Liquid Wax
Processes given below prevent these problems and assist you in keeping
your mold in production longer to get better productivity. This translates
into reduced costs, better bottom lines and increased profits.
ONCE MOLD IS PROPERLY PREPARED ACCORDING TO
PROCEDURES OUTLINED EARLIER (NEW MOLD PREPARATION OR
REJUVINATION OF OLD MOLDS) AND MULTIPLE RELEASES CYCLE
IS WORKING, PLEASE FOLLOW ONE OF THE PROCESSES BELOW
THAT IS APPROPRIATE FOR YOUR OPERATION:
PROCESS 1: Apply #1000L: Hi-Low Liquid Wax to the mold over the paste
wax when the part gets a little hard to pull between multiple releases. Use
of #1000L will liquefy old wax and will reactivate it to make it a part of the
mold release agent, thereby avoiding the wax buildup. Thus, the application
of #1000L will reduce surface tension, keep the proper amount of Hi-Low
Wax on the mold and will achieve problem free and easy releases.
PROCESS 2: FK recommends reapplication of a Paste Wax or mold release
agent, over the entire mold along with the application of Liquid Wax
after 6-8 releases. Then revert back to use of only #1000L, Liquid Wax.
Therefore, use of Liquid Wax (#1000L) on a regular basis will deter wax
buildup and most importantly surface tension by keeping a fresh coat of
release agent on the surface for better & easy releases.
PROCESS 3: The inevitable thing is that wax will builds up no matter what
care or precautions you take. So, when wax build-up does take place,
areas of dullness will appear and surface tensions will develop around
deep corners, contours and radiuses and parts will become a little harder
to pull. At this time redo the complete cleanup procedure to prepare
the mold. Use either #69 or #135-80 to clean the mold thoroughly by
agitating and wiping while wet. Two or three coats may be necessary. This
will remove the wax build-up and reduce the surface tension. Then, apply
3 to 4 coats of Mold Release agent (either #1000P or any other paste wax
or #135T) and put mold into production. Following these processes will
assure prolonged mold use and will give trouble free and easy releases.
Thus, the total work will be reduced and you will achieve more production
with better profitability.
T: 626-443-8983 • F: 626-443-0288
www.FinishKare.com
– 16 –
FINISH KARE OFFERS THE MOST COMPLETE LINE
OF MOLD PREP and MOLD RELEASE PRODUCTS:
Finish Kare
TR
Meguiar’s
Rexco
Specialty
CLEANERS:
#69 Mold Cleaner & Stripper
TR 210
NO COMPARABLE PRODUCTS
#80 Liquid Mold Cleaner
#135-80 Polymer Mold Cleaner and Wax
Remover
TR 905
KantStik
Mold Cleaner
MOLD SEALANT:
#86 Seal Kote
MOLD RELEASE AGENTS
#135T Semi-Permanent Polymer Based
Release Agent
TR 900
#135ER Urathane Release
#333MR Mold Release Paste Wax
TR 102/ TR 108
MGM 16/88
TR 104
NO COMPARABLE
PRODUCTS
#888 Max Mold Release Paste Wax
#1000P Hi Low Paste Wax
Mold Release
Wax
Honey Wax &
H. Plus Wax
Partall
Hi-Tem Wax
Honey Wax &
H. Plus Wax
#8
#1004-23 Brush Gel Coat Release Paste Wax
#1006 Mold Release Paste Wax
#1165 Hi Temp Stability Extra Hard
Premium Wax
# 1004-23 Brush Gel Coat Release Paste Wax
#1000L Hi Low Liquid Wax
TR 214
#1000L-28 Sprayable Heavy Duty Mold
Release Wax
Golden Wax Liquid
COMPOUNDS & POLISHES
#103 Extra Heavy Duty Cleaner
#923 True Image Polishing Compound
M0364
#600 White Fine Rubbing Compound (Paste)
#440-5 Polishing Compound
TR 311
M0164
#330 Mini Buff
TR 308
TR 110
OTHER WAXES & PRODUCTS
#68 Edge Wax
#604-B Mold Sealer & Release Wax
#626 Hat Wax
TR 111
#332 Hand or Spray Interphase Releas Wax
PB-1Traffic Wax
#64 PVA Clear/#65 PVA Blue
#67 PVA Green
KantStik EP
TR 504
PV-6 Film Agent
Partall Film # 10
Please note that this comparision is not based on actual chemical analysis, but according to comparative use properties .
– 17 –
KantStik C
For product inquiries, questions or sample requests, please contact:
1726 Floradale Ave., So. El Monte, CA 91733 USA T: 626-443-8983 • F: 626-443-0288
www.FinishKare.com
email: [email protected]
Please feel free to copy any of the procedural pages for shop personnel.
Hang in the work area for easy reference and better demolding.
– 18 –

MOLD RELEASE PRODUCTS: MOLD PREPARATION

Transcription

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