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    Spray Up Molding

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    neelagaantan
    Spray-up plastic molding is a process that uses spray guns to apply a mixture of plastic resin, reinforcement materials like glass fibers, and a bonding agent onto molds. The mixture is carefully regulated to ensure uniform coating. There are different types of spray guns that mix the materials internally, externally, or via turbulence. Selecting the proper spray gun is important for efficiently applying the materials and achieving quality spray consistency. Operator safety is also crucial when using spray-up techniques.

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    Spray Up Molding

    Uploaded by

    neelagaantan
    76 views2 pages
    Spray-up plastic molding is a process that uses spray guns to apply a mixture of plastic resin, reinforcement materials like glass fibers, and a bonding agent onto molds. The mixture is carefully regulated to ensure uniform coating. There are different types of spray guns that mix the materials internally, externally, or via turbulence. Selecting the proper spray gun is important for efficiently applying the materials and achieving quality spray consistency. Operator safety is also crucial when using spray-up techniques.

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    Spray-up plastic molding is a process that uses spray guns to apply a mixture of plastic resin, reinforcement materials like glass fibers, and a bonding agent onto molds. The mixture is carefully regulated to ensure uniform coating. There are different types of spray guns that mix the materials internally, externally, or via turbulence. Selecting the proper spray gun is important for efficiently applying the materials and achieving quality spray consistency. Operator safety is also crucial when using spray-up techniques.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as DOCX, PDF, TXT or read online from Scribd
    Download as docx, pdf, or txt
    76 views2 pages

    Spray Up Molding

    Uploaded by

    neelagaantan
    Spray-up plastic molding is a process that uses spray guns to apply a mixture of plastic resin, reinforcement materials like glass fibers, and a bonding agent onto molds. The mixture is carefully regulated to ensure uniform coating. There are different types of spray guns that mix the materials internally, externally, or via turbulence. Selecting the proper spray gun is important for efficiently applying the materials and achieving quality spray consistency. Operator safety is also crucial when using spray-up techniques.

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    Spray-Up Plastic Molding

    Many types of molding processes


    employ reinforcements that are
    bonded to the base plastic resin,
    making the molded product stronger
    and more durable. The reinforcement,
    resin, and bonding agent can be
    applied to the mold in a number of
    ways, ranging from manual methods
    to automated positioning. The spray-
    up technique incorporates a spray-gun
    mechanism that can be used under either operator or computer control,
    and has remained a popular peripheral procedure in industrial molding
    since the mid-twentieth century. It allows for careful regulation of material
    deposits and can be a highly effective method in reinforced plastic
    fabrication.

    Reinforced spray-up products are often used as support components for


    solid structural and non-structural applications. The spray gun itself is
    usually equipped with a roller chopping mechanism that cuts glass fiber
    into short strands, which are then distributed along the surface of the mold.
    Advances in spray technology have led to more efficient and cleaner
    spraying systems, with reduced styrene emissions, greater spraying
    capacity, and higher uniformity among spraying patterns. The guns come in
    a variety of configurations, each with its own distinct capabilities.

    Spray Gun Specifications

    The resin compound fired by the spray gun is usually mixed with a catalyst
    agent, such as thermosetting polyester plastic, and air is often included in
    the ejection. Glass fibers are chopped by a cutting mechanism within the
    gun and may receive a plastic coating as they pass through the nozzle. After
    the mixture is sprayed onto the mold, serrated rollers are used to remove
    any air pockets or voids. Some of the common types of plastic molding
    spray guns include:

    • Internal Mixing Guns: These guns feature two separate channels for the
    catalyst and the resin, which intersect and mix together in the firing nozzle.
    The spraying system is airless and uses low pressure to disperse a precise
    pattern with a low chance of over-spraying the targeted area.

    • External Mixing Guns: The external mixing configuration also uses


    separate channels for the resin and catalyst, but they do not intersect within
    the nozzle. Instead, smaller particles of resin and catalyst are fired from
    separate nozzles and mix outside the spray-head, with an additional
    channel for air. Because the mixing occurs externally, the nozzles have to be
    angled precisely to achieve the right combination of materials.

    • Turbulence Mixing Guns: In this format, an air injection causes


    turbulence that creates small droplets within the spray-head. These
    droplets help widen the spraying pattern, distributing small particles across
    a relatively expansive area.

    For an example of these mixing guns in action, watch the video below:

    Spraying Equipment

    Most spraying systems use a double-action pump to collect resin from a


    storage drum. The resin is filtered through a specialized mesh screen that
    regulates and maintains an even flow of material. Likewise, the catalyst is
    also drawn using a double-action pump, but with air pressure pushing back
    against the pump mechanism. The catalyst-to-resin ratio can be controlled
    at the pumps to ensure a precise proportion of each material in the spray
    gun. The chopping unit within the gun distributes an even amount of cut
    glass fibers through the spray, resulting in relatively small amounts of
    trapped air as the glass is delivered to the mold’s surface.

    When considering different types of spray guns for a project, it is important


    to select a device capable of accurately cutting and mixing the materials, as
    well as offering safe and effective operating parameters. Purchasing
    suitable equipment can mean more efficient use of forming materials, such
    as resin, glass, and catalyst, thus saving on production expenses.

    Spray Quality

    A spraying system can apply several layers of material to achieve the


    required thickness for the coating, but the quality and effectiveness of the
    spray is largely dependent on its consistency. For this reason, it is
    important to remove any trapped air with rollers or other smoothing
    devices. The spray can be applied both indoors and outdoors, and can be
    used to add reinforced coatings and corrosion resistance to molds and other
    components. However, because the spray particles are released into the air,
    it is crucial for manual operators to wear safety gear, particularly face-
    masks and breathing apparatuses, in order to protect themselves from
    potentially harmful chemicals, such as styrene vapor. In the U.S., the
    Environmental Protection Agency and the Occupational Safety and Health
    Administration provide standards and regulations for spray-up processes.

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