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Commentator

Join Date: Apr 2005
Location: Phoenix, AZ
Posts: 82
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Mold Modification

10/15/2012 11:30 PM

We mold layered dynema in an aluminum mold. The powers that be dictate we make two parts per mold, by laying in the first part, then "piggy-backing" the second one on top. The downside to this approach is tranfer of impressions and inperfections from one part to the other. We have an idea that if we put a material between the two parts, it will negate this issue. The parts are not flat, so this becomes quite an exercise.

The pressure applied on the parts when loaded in the mold is >4000 PSI, temperature >280 F. The material used to separate the parts in the mold can be as great as 3/8" thick. The question becomes what kind of material compostion is suitable for this application?

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Guru

Join Date: Oct 2008
Posts: 42355
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#1

Re: Mold modification

10/15/2012 11:49 PM

It's Dyeema®

What's wrong with using bleeder cloth and release cloth to separate the parts?

If you want real help, you will have to provide real details.

Be specific. Thickness of plys. Number. Lots more detail.

Why put something 3/8" thick in a mold that has to heat cure parts?

What is your level of experience?

Laying a second part over the first one will change all the proportions and relative thickness of the parts by the thickness of each layer.

The second part will not be like the first one.

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Commentator

Join Date: Apr 2005
Location: Phoenix, AZ
Posts: 82
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#4
In reply to #1

Re: Mold modification

10/16/2012 12:45 AM

On first contact for info, I was and am reluctant to give great specifics, due to severe restrictions on processes info. If you give up too much info, you just made somebody a market to compete against you.

I chose 3/8" T61 aluminum due to its strength, and the belief that it would withstand the pressure and temperature w/o deformation. You have to have a starting point and work from there. My concern is the smoothness of the face of the finished product.

I have not seen evidence of relative thickness differences using the process I am using now. Both parts mic out very close to each other. The number of layers differs with the class designation of the particular order. It can very from class 2 to class 4.

Bleeder and release cloth will not negate the issue I have. The cure time negates the issue of uneven heat from experience. If we use a secondary approach, an autoclave, most certainly, uneven heat distribution is a non-issue. There are many downsides to using this approach, so it is not at the top of the list.

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Guru

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#5
In reply to #4

Re: Mold modification

10/16/2012 9:29 AM

It sounds like all you need is some way to heat the divider plate.

I'm assuming that cartridge heaters can't be used, because the parts are contoured.

Don't know if you could somehow put passages in the plate and pump hot oil through it.

Does NIJ mean anything to you?

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Location: Richland, WA, USA
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#2

Re: Mold modification

10/15/2012 11:59 PM

Let's combine forces and get Dyneema®

--Ed. C.

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Guru

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#3
In reply to #2

Re: Mold modification

10/16/2012 12:14 AM

I hate it when I'm wrong. Dyneema® it is.

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