FAQ FRP Process FRP Terms Trouble Shooting

FRP Process  

Hand Lay-Up
The oldest and simplest molding technique in which reinforcing materials and catalyzed resin are laid into or over a mould by hand. These materials are then compressed with a roller to eliminate entrapped air. The process of hand placing successive layers of reinforcement and resin in to an open mould resulting in a part with one finished surface.

The main advantages of this process are :

  • Low Investment, any types of large and small parts can be made, short tooling lead time & higher glass content is possible.

The main dis-advantages of this process are:

  • It is totally labour intensive, operator dependent, thickness variations & material waste.
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Spray-Up
It covers a number of techniques in which a spray gun is used to simultaneously deposit fiberglass and catalyzed resin on a mould. The process of spraying chopped fibers and resin, in place of mat type reinforcements, into an open mold resulting in a part with one finished surface is called Spray-up. It is used in Conventional Gun Rovings.

The advantages of this process are :

  • Higher output than hand lay-up
  • Large and small parts, Short tooling lead time

The disadvantages of this process are :

  • Higher investment than hand lay-up
  • Emissions
  • Material waste
  • Operator dependent
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BMC(Bulk Moulding Compound)
A combination of resin paste and chopped glass combined with a "sigma" blade mixer under conditions of very high mechanical "working" stress. The compound is delivered to the press in the form of a ball, slab or an extruded log and dropped into the bottom of a mould; the material is flowed outward until it assumes the shape of the mould.

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Filament Winding
The process of helically (spring like) wrapping reinforcements and resin around a polar mandrel. They are typically used for Conventional Multiple-Bundle Rovings & Surface Veils.

The main advantages of this process are :

  • Low labor
  • High strength orientation
  • high part output
  • Reproducibility

The main dis-advantages of this process are :

  • High investment
  • Unsuitable for comples shapes
  • One smooth surface
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Pultrusion
The process of continuously pulling a resin-impregnated reinforcement through a die in to its final shape. This is typically used for continuous Strand Mat and Surface veils.

The main advantages for this process are :

  • Low labor
  • Low waste
  • Versatility of reinforcement distribution

The dis-advantages of this process are :

  • High investment
  • Long tooling time
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Resin Transfer Moulding(RTM)
The process of injecting resin in to a closed mould already containing the reinforcement resulting in two finished surfaces is RTM. It is typically used for continuous Strand Mat

The advantages of this process are :

  • Two furnished surfaces
  • Low emissions
  • Low investment (compared to other moulding)
  • Thickness control

The disadvantages of this process are :

  • Slow mould cycle
  • Special tooling requirements
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SMC (Sheet Moulding Compound)
An integrated, ready-to-mould fiberglass reinforced polyester material. The compound is composed of a filled thermosetting resin and a chopped or continuous strand reinforcement. The primary use is in matched die moulding and for Conventional rovings.

The advantages of this process are :

  • Higher strength laminate
  • Ability to mould larger parts (compared to BMC)

The disadvantages of this process are :

  • Higher investment
  • More technology required
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Compression Moulding
The process using matched metal dies under pressure to form the reinforcement and resin in to the finished part is Compression moulding. This process is suitable for moulding complex, high strength fiber glass reinforced parts using preforms, sheet moulding compound (SMC) or bulk moulding compound (BMC). It is typically used for Continuous Strand Mat, Sheet Moulding Compound (SMC) and Bulk Moulding Compound (BMC).

The advantages of this process are :

  • High Volumes
  • Excellent surface finish
  • Moulding complex, high-strength large parts
  • Two finished surfaces
  • Part consistency

The disadvantages of this process are :

  • High investment
  • Long tooling time
  • Requires pre-processing of the molding material
 

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