POLYLITE® PROFILE POLESTER RESIN TOOLING MANUAL
64Pages

» Scope of this Manual A revolutionary new polyester material and process technique has been developed that produces a production and process-ready composite tool in typically 80% less time than conventional polyester tools. These tools, used in the production of open mold fiberglass hand lay-up/spray-up and resin transfer molding (RTM) parts, have for years required weeks of painstaking, labor intensive, hand lay-up of one or two layers at a time of resin-impregnated fiberglass mat reinforcement. This new material represents a breakthrough in reducing the lead time from concept design to part production. This manual documents the proper techniques and procedures in constructing composite molds made from Polylite® Profile Tooling Polyester Resin and demonstrates the cost effectiveness of the resin compared to traditional polyester resins. Intended Audience Both pattern and tool makers will find this manual useful in the construction of composite tools and prototype parts. Part Detailers, Industrial Designers and Engineers will also find the manual informative in designing parts that are truly production ready. Reichhold Reichhold is the world’s largest supplier of unsaturated polyester & vinyl ester resins used by the automotive, boat-building, wind energy, industrial, corrosion, flame retardant, leisure and tool making industries. For further information about Reichhold’s product offerings contact your nearest Reichhold representative.

Polylite® Profile System Advantages Tool Construction Technology System Comparison Tool Construction Technology—Steps Resin Compound Formulation Trouble shooting System Recommendations Approved Application Equipment Typical Polylite® Profile Resin Properties Approved Fillers | Approved Glass Reinforcement Typical Polylite® Profile Resin Physical Properties Resin Compound Mix Proportions Technical Tips Promoter Levels Versus Gel Time and Temperature Initiator Levels Versus Gel Time and Temperature Packaging / Safety / Quality / Storage Polylite® Profile Distributors Corporate Headquart

33540 Series Polylite® Profile 33540 Series is a non-promoted, non-thixotropic, unsaturated polyester laminating resin. Polylite Profile 33540 Series is suitable for construction of FRP tooling. The resin is formulated for room-temperature curing with Superox® 46750 peroxide initiator and is to be used with specific alumina trihydrate fillers. Polylite Profile 33540 Series must be promoted with Reichhold 46559 cobalt-based promoter solution prior to initiation. FEATURES BENEFITS Tools can be built in 80% less time Significantly reduces labor costs Production start-up time reduced...

33541 Series Polyilte® Profile 33541 Series is a promoted, non-thixotropic, unsaturated polyester laminating resin. Polyilte Profile 33541 Series is suitable for construction of FRP tooling. The resin is formulated for room-temperature curing with Superox® 46750 peroxide initiator and is to be used with specific alumina trihydrate fillers. FEATURES BENEFITS Tools can be built in 80% less time Significantly reduces labor costs Production start-up time reduced Makes prototype tools rapidly and economically Low Shrinkage Tool reproduces master exactly Resulting tool is stress free...

REICHHOLD » Polylite® Profile System Advantages Polyilte® Profile 33542 Series is a promoted, thixotropic, unsaturated polyester laminating resin. Polyilte Profile 33542 Series is suitable for construction of FRP tooling. The resin is formulated for room-temperature curing with Superox® 46709 peroxide initiator or other approved peroxide initiators. FEATURES BENEFITS Tools can be built in 80% less time Significantly reduces labor costs Production start-up time reduced Makes prototype tools rapidly and economically Low Shrinkage Tool reproduces master exactly Resulting tool is...

This chart represents two major areas of benefits using the Polylite® Profile Tooling System versus standard resin used in production tooling. A typical tool can be produced at a system cost savings of approximately 50% compared to conventional laminating resins and tool making methods. The savings is passed on in both labor and materials. In addition to a system cost saving, a production time savings of up to 80% is also realized by using the Polylite Profile system. System cost is reduced by 50% with the Polylite Profile System I Standard Production time is reduced by 80% with Polylite Profile...

» Resin Compound Formulation » Resin Compound Formulation 33540 Series COMPOUND Polylite® Profile 33540 Series Resin 100 parts Alumina Trihydrate Filler 100 parts Reichhold 46559 Promoter 0.4-0.8 parts, based on resin weight Superox® 46750 Peroxide Initiator 1.25 parts, based on resin weight Fiberglass Roving 18-22% of laminate weight When mixing a 55 gallon drum of resin (net weight 300 Ibs), the following formulation should be followed: Polylite Profile 33540 Series 300 lbs (136.08 kg) Alumina Trihydrate Filler 300 lbs (136.08 kg)

COMPOUND Polylite® Profile 33541 Series 100 parts Alumina Trihydrate Filler 100 parts » Resin Compound Formulation33541 Series Superox® 46750 Peroxide Initiator 1.25 parts, based on resin weight Fiberglass Roving 18-22% of laminate weight TYPICAL EXAMPLE When mixing a 55 gallon drum of resin (net weight 300 Ibs), the following formulation should be followed: Polylite Profile 33541 Series 300 lbs (136.08 kg) Alumina Trihydrate Filler 300 lbs (136.08 kg)

Resin Compound Formulation 33542 Series COMPOUND Mix Requirements Polylite® Profile 33542 Series Prefilled & Promoted 100 parts Note: Superox® 46709 Peroxide Initiatior is not to be mixed into the resin/filler mix but metered through the chopper gun. Superox 46709 Peroxide Initiator 1.25 parts, based on resin weight Fiberglass Roving TYPICAL EXAMPLE When mixing a 55 gallon drum of resin (net weight 300 Ibs), the following formulation should be followed: Polylite Profile 33542 Series Polylite Profile must be agitated or mixed well to ensure even filler distribution. A “bunghole” mixer is not an...