Tooling for Closed Mould Processes

Tooling for Closed Mould Processes
tl +44 (0) 1752 849998
fx +44 (0) 1752 849808
[email protected]
www.composite-integration.co.uk
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Founded in 2002 by Richard
Bland and Stephen LeonardWilliams
Over 40 years combined
practical experience of ‘closedmould’ composite processing
World wide distribution in more
that 20 countries and exporting
more than 40% of output
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Turnover £1.8 million
15 employees
Purpose built 9000ft² facility in
Saltash, Cornwall
ISO 9001 accredited
Members of the National
Composites Centre
Providing:
• Injection equipment for
RTM processes
• Equipment for infusion
processes
• Vacuum equipment
• Moulds/Tooling
• Data monitoring
systems
• Training and technical
support
Our customers include:
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Our customers include:
• General composite moulders
• Marine manufacturers
• Aerospace and military
manufactures
• Automotive manufacturers
• Architectural manufactures
• Universities
• Research establishments
Why consider a ‘Closed Mould’ process?
Advantages:
•Control of A and B surfaces
•Resolves environmental and H&S issues
•Control of thickness
•Control of laminate quality
•Improved cycle times
•Repeatability
•Process can be de-skilled
•Process can be automated
•Relatively Low cost tooling
Which ‘Closed Mould’ process are we talking about.......?
•CIRTM
•VI
•DRDF
•LRI
•MVI
•Quickstep
•RI
•RIM
•RFI
•RIFT
•RIRM
•RTM
•HPRTM
•C-HPRTM
•RTMS
•RTM Light
•SCRIMP
•RVBM
•Flex Moulding
•VAIM
•VAP
•VARI
•VARIM
•V(A)RTM
•VIM
•VIMP
•VIP
•VRTM
•Infujection
Co-Injection RTM
Vacuum Infusion
Double RIFT Diaphragm Forming
Liquid Resin Infusion
Modified Vacuum Infusion
Use of liquids for enhanced heat transfer in infusion
Resin Infusion
Reaction Injection Moulding
Resin Film Infusion
Resin Infusion Under Flexible Tooling
Resin Injection Recirculation Moulding
Resin Transfer Moulding
High pressure Resin Transfer Moulding
Compression High Pressure resin transfer Moulding
RTM variant with integrated Thermoplastic surface
Semi-rigid tooling- vacuum clamped
Seeman Composites Resin Infusion Moulding Process
Reusable Vacuum Bag Moulding
Reusable vacuum bag moulding
Vacuum-Assisted Injection Moulding
Vacuum Assisted Processing
Vacuum Assisted Resin Injection System
Vacuum Assisted Resin Injection Moulding
Vacuum (Assisted) Resin Transfer Moulding
Vacuum Infusion Moulding.
Vacuum Infusion Moulding Process
Vacuum Infusion Process
Vacuum RTM (rigid or semi-rigid tooling vacuum clamped)
Direct mechanical Injection of resin into infusion process
Vacuum-Bag infusion
Vacuum-Bag infusion (from meter-mixing machine)
Vacuum Resin Transfer Moulding (VRTM or RTM Light)
Resin Transfer Moulding (RTM)
Vacuum
Catch Pot
Injection
Valve
Injection
Machine
Vacuum
System
Mould
Typical VRTM Production cell
VRTM- Typical moulding process
Air Ejector (to assist
de-moulding)
Lower (female) Mould
Fibre (and foam core) loaded
Injection Valve
Catch-pot
Double vacuum
seals
Upper mould located against lower
mould
Mould Closing
Mould Closing
Mould Closing
Vacuum connected to
flange area
Regulated vacuum
connected to catch-pot
Injection valve connected
to machine
Mould Closed and Vacuum
connected
Resin injected at controlled
pressure (via Injection Valve) into
peripheral runner
Resin flowing peripherally from
runner
Final mould fill at catch-pot
Vacuum maintained during resin
cure
Mould opened
Tooling Options:
• Machined metal (aluminium, steel)
• Electroformed metal (nickel)
• Composite (cast)
• Composite (laminated)
RTM Tooling
Factors to consider:
• Production volume
• Injection and venting strategy
• Fibre loading strategy
• Tool orientation
• Accessibility
• Fibre loading
• Temperature control
• Thermal expansion
• Surface finish
Composite Tooling:
Choosing the best materials.....
•Surface finish
•Toughness/damage resistance
•Heat resistance
•Chemical resistance
•Stability (minimal shrinkage)
•Usability/practicality
Composite Tooling:
Material options
•Polyester (High shrinkage, poor temperature resistance,
limited mechanical properties. Easy to use)
•Epoxy (Low shrinkage, good temperature resistance, and
mechanical properties but difficult to achieve excellent
surface finishes. Limited chemical resistance and can be
complex to use)
•Vinylester (Reasonable mechanical properties and
temperature resistance. Good chemical resistance plus
reasonable stability. As easy to use as polyester)
Building a composite VRTM mould
Key stages:
The Master-Pattern
Applying tooling gelcoat
Laminating the ‘skin-coat’
Laminating the supporting layers with a low-shrink resin system
Adding a supporting frame
Removing the Master-Pattern
Representing the product thickness in sheet-wax
Building the flange seal groove and resin-runner details
Starting to laminate the second mould half
Laminating the second mould half
Separating the two mould halves
Removing the sheet wax and seal formers
Polishing and applying release agent
Fitting the resin seal and vacuum seal
Example: process/tooling options- complex tray component.
Example: Disposable vacuum bag infusion? Low cost tooling but difficult technique on such a complex
shape. Poor control of ‘B’ surface laminate finish.
Example: Reusable vacuum bag infusion? Much more convenient and significantly quicker
than disposable vacuum bag. Limited control of ‘B’ surface laminate finish.
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Follow this link to see a video showing the
construction and use of a composite VRTM mould.
http://www.youtube.com/watch?v=f-vBw3HH7uI
Example: Two-part VRTM Mould: Fast, efficient and excellent control of ‘B’ surface laminate finish.
Heated Composite tooling:
Steel supporting structure
Frame bedding mixture
GRP Laminate
Flexible bonding interface
Core layer
Thermally conductive layer
Copper pipe
Main surface laminate
Surface tissue
Tooling Gelcoat
Metal tooling:
•High volumes
•High pressure
•High temperature
•Complex geometry
Metal Tooling in operation: High volume production of composite door skins.
Unit 1 Burraton Road
Saltash Parkway Industrial Estate
Saltash, Cornwall, UK, PL12 6AY
 +44(0)1752 849998
 [email protected] 
www.composite-integration.co.uk