b'STAGE1 Plug PreparationThe first step in fibreglass mould making is to make a plug.If the mould is to see high temperatures and a post cure is PRODUCT DESCRIPTION APPLICATION The plug for a fibreglass or composite mould is usually an exactnecessary on the plug then your selection of materials will change. representation of the finished part, and can be an actual part or aIn this brochure we focus on making tools that are used extensively mock up of a part. In planning for the mould certain factors mustfor producing Polyester Resin hand lay, spray lay up, closed mould Norester 6779 Plug Laminating Resin Suitable for Polystyrene Plugs (non Thixo) be taken into consideration; surface finish, draft angles, undercuts,or other RTM andresin infused parts. Plugs made from scratch can and method of production. A composite mould that is going tobe done from a wide variety of materials using a wide variety of NCL 809 Sprayable CNC Putty Apply to min thickness of 8mm(2 layers) for machining be used for vacuum infusion or closed-moulding processes willmethods. There are many examples of making a plug from scratch require large flanges. Parts that are undercut or have negative draftand taking it all the way through making a mould. From a foam will need to be done in two part moulds for them to be able to becore, to plywood to make the flanges, and glassed over to provide NCL 815 Extrudable CNC Putty Apply to Final thickness of 12mm for machining (3 layers) extracted from the mould. Composite moulds that are designeda stable surface to fair over. You can use MDF to make plugs, high to be used with carbon fibre parts often need to be made out ofdensity foam, polystyrene, body filler, and other materials. Nord 230BV Primer Plug Primer (Sprayable) Apply 450-600 Microns carbon fibre in order to match the coefficient of thermal expansion,For large parts often a framework is built and then layered with especially if during the moulding process the part and mould willfoam, fibreglass, and body filler before priming and finishing.Nord GC 210 Sprayable Plug Lacquer Apply several thin layers to the primed plug be heated to cure and then cooled to demould, i.e. prepreg parts. Roar Extreme 900/ Extreme 910 Polishing Compounds For compounding from 800 grit sandingTek-Kote Mould Cleaner Mould Cleaner Solvent Wipe on Wipe Off Forming the PlugTek-Kote Mould Sealer Semi Permanent Mould Sealer Wipe on Leave On or Wipe on Spread 1:Machine the chosen base (Polystyrene, Polyurethane,Tek-Kote Fast Release Semi Permanent Release Agent Wipe on Leave On Timber etc).2:Apply 2 layers of the Resin (Norester 6779) using 300gNorester GC 200 Gelcoat Iso Tooling Gelcoat (Brush Apply) For low volume cycle moulds powder bound mat. Laminate 10-15cm wider than the4plug. Allow to cure for 24hrs before applyingsprayable putty NCL 809 or extrudable putty NCL 815. Norester GC 201 Gelcoat Iso Tooling Gelcoat (Spray Apply) For low volume cycle moulds Spray with a Graco type machine (pump ratio 20:1) Use several thin passes until you achieve 5-6mm . Norester GC 206 Gelcoat Vinyl Ester Tooling Gelcoat (Brush Apply) For high cycle moulds & high temp resist Final dimensions for CNC machining should be 8-12 mm. 3Norester GC 207 GelcoatVinyl Ester Tooling Gelcoat (Spray Apply) For high cycle moulds & high temp resist 3:After machining apply Nord 230BV primer (several finepasses 450-600 microns) then sand to a smooth finish.For low shrink and high surface finish good mechanicals4:Spray several coats of Nord Lacquer 210 to achieve a 2Norester 6842 Vinyl Ester Resin Vinyl Ester Skin Coat (Clear Thixo) and chemical resistance high gloss finish.Norester 6800 Vinyl Ester Resin Vinyl Ester Skin Coat (Clear Thixo) For low shrink and high surface finish good chemicalThen sand with a fine paper. Finally you can then compound resistance and high flexural strength the lacquer using Roar 900 and 910 polishing compound1with a machine polisher.PRODUCT DESCRIPTION APPLICATIONNoresterDescription: Low Styrene content PolyesterA low cost system. 2.5 : 1 Resin to Glass.8600 TA 35 laminating resin ready to use speciallyIdeal for low volume cycle moulds. GC210 PRIMER POLISH FOR GLOSS FINISHrecommended for the production of Moulds using Hand Lay Up or Spray Application. Thixotropic, preOnce the plug is prepared and de-greased usingWet and dry your plug to the required standard and accelerated ready to allow the quick production ofTEK-KOTE Mould Cleaner, Spray GC210 Primer togloss finish, polish with mop and Roar 900 and 910 moulds. Excellent fibre wet outand impregnationrequired thickness. cutting paste to level required for production needs.with a glass to resin ratio of 1:2. Excellent mechanical properties useful for light weight tools.NoresterTooling Resin formulated from an unsaturatedExtensively used in the Marine industry. 4 : 1 Resin to glass.RMpolyester resin. It is filled, promoted andApply min thickness of 8mm (2 layers) for machining.2000/50 pre-accelerated. Formulated for mould making. NoresterTooling Resin based on polyester resin forA rapid tooling resin with good surface appearance. Good curing.RM 2550 the production of composite moulds with lowGood mouldability, and fast wet out, resin to glass ratio 2.5 : 1 Creates shrinkage. It is a product ready to use, filled andLighter moulds with better mechanicals properties hence lower tooling pre accelerated resin costs. Superior mechanical properties due to a glass content approximately 28% higher than with conventional tooling resins.NoresterVinyl Ester Hybrid Tooling Resin especiallyDesigned to polymerize at room temperature following addition of RM 3000 formulated for producing composite moulds fornormal MEKP catalysts.Resin pre-accelerated and promoted, permits applications where high thermal and chemicala fast curing and a rapid manufacture of moulds.An easy to use resistance are required product with low shrinkage hence high surface finish of the finished mould/parts.Fast build up of Barcol hardness. Improvement of the mould rigidity and low cost of mould production. Low exotherm curing system.Low viscosity.'