Step-by-step guide
Preparation
- Figure out materials
- Reinforcement
- For S22-S24 we used foam molds to make a fiberglass tool.
- Reinforcement needs to be precut beforehand to the right size
- Resin
- Pot life determines how long you have to work with the resin in a pot/bucket before it starts to cure. Higher pot life gives more leniency
- Reinforcement
- Sanding: We want the mold to be as smooth as possible. Sanding gives a clean finish that's close to the CAD and makes it easier to demold
- Spackling
- Apply Joint Compound:
- This needs to be lathered all over the mold in 3 layers. Miss no spots
- Apply Primer: this seals the mold
- Use paint rollers; this will give an even coat of primer
- Apply mold release
- In the past we have used PVA. Historically this has rarely worked on a foam mold.
- Gather all consumables
- Gloves: protection from resin
- Disposable aprons: protection from resin
- Stir sticks
- Paint brushes: used to apply resin
- Cheap and disposable. Don't reuse these
- Buckets: to hold the resin
- Scales: to measure the resin
- Make sure you know how many people are coming beforehand
- Make sure they have the required PPE (respirators)
- Assign them roles
- Resin mixers
- Resin appliers
- Fabric appliers
- Overseers
Conducting the layup
- Make sure everyone has PPE on correctly
- Check respirators to make sure there is no leakage
- Mix resin and hardener together according to the ratios given on the SDS or on the packaging
- Apply peel ply
- Apply breather
- Apply vacuum bag
Common issues
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