easycomposites Uni-Mould Universal Moulding System

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INTRODUCTION AND APPLICATION GUIDE

Advantages Application Guide

• Low cost system ideal for all size moulds This step-by-step application guide assumes that your pattern or master
is made from a suitable material, is fully cured, sealed and prepared with
• Epoxy and polyester compatible a suitable release agent.

• High dimensional stability The guide assumes a mould of 1-2sqm. For larger moulds (up to the size
of full boat hulls) the Uni-Mould system is still ideal but special measures
• Long-life moulds need to be undertaken when applying the mould reinforcement. Please

• Highly polishable hard-wearing surface contact us for more details.

• No special equipment or processing

Uni-Mould Tooling Gel Coat Application
Uni-Mould™ Advantages Uni-Mould Tooling Gel Coat should
be catalysed at 3% using standard
Traditionally, moulds made using polyester resin and gel coat are MEKP catalyst. Before application
unsuitable for use as moulds for epoxy-based parts due to well-known allow the catalysed gel coat to
release problems when used in this combination. Most polyester moulds stand for a few minutes to settle
also suffer from distortion (pulling), particularly on larger moulds, and and de-gas.
cannot be used at elevated temperatures, making them unsuitable for Gel coat should be applied in
in-mould post-curing. two applications. For the first
Uni-Mould is different. It features unique vinylester chemistry which is application aim for a consistent
100% compatible with epoxy, vinylester, polyester and pre-pregs making thickness of 0.3–0.4mm. Allow the
it a genuinely universal tooling system. Its specially formulated resin first application to cure for around
systems are designed to be dimensionally stable up to the Maximum 2-3hrs (at 20°C room temperature)
Service Temperature of 90°C and will not pull as they cure resulting in
more dimensionally accurate moulds. before applying the second coat of gel coat, again aiming for a thickness
Moulds made using Uni-Mould are highly polishable and, in combination of 0.3 - 0.4mm.
with a chemical release agent (such as Easy-Lease), will result in high- Allow the gel coat to cure for a minimum of 4hrs (at 20°C room
gloss parts straight out of the mould, time after time. temperature), preferably overnight..
Uni-Mould is designed to be used with low-cost emulsion bound glass
chopped strand mat (CSM) reinforcement which breaks down excellently Uni-Mould Coupling Coat Application
in the resin, just like it would with a polyester resin, meaning that it is an
ideal and cost-effective way to create medium to large moulds.

Use with Prepregs

Although it is possible to use Uni-Mould moulds with out-of-autoclave
(oven cure) prepregs (such as XPREG® XC110) we no longer recommend
Uni-Mould moulds for this purpose.
Instead – for prepreg use – better results will be achieved using high
temperature epoxy moulds made using our EG160 / EMP160 tooling
The Uni-Mould Coupling Coat is designed to eliminate print-through of
system or XPREG® XT135 Tooling Prepreg. These high temperature epoxy
the mould reinforcement, to reduce the risk of blisters underneath the gel
tooling systems allow the prepreg to be cured at the optimum 120°C
coat by ensuring the gel is reinforced with a skin of resin and glass and to
which reduces the cure time and improves the mechanical properties of
provide an ideal substrate for the main reinforcement.
the component. Additionally, epoxy tools have been found to result in a
better surface finish with prepregs such as XPREG® XC110. Uni-Mould Coupling Coat should be catalysed with standard MEKP at 1.5
– 2%. Apply a layer of the coupling coat over the mould surface and then
add a single layer of 150g CSM. We do not recommend the use of glass
The Uni-Mould™ System surface tissue in lieu of the 150gsm CSM.
Wet out the CSM thoroughly with the coupling coat resin and ensure that
The Uni-Mould system is made up of 3 specially formulated resins, all
all air is removed from the reinforcement, that it is well wetted through
capable of high operating temperatures and filled for zero shrinkage:
and that the reinforcement is conforming to all the contours of the
Uni-Mould Tooling Gel Coat (single or double application to 0.8mm) mould, particularly any tight corners.
Uni-Mould Coupling Coat (used with 1 layer of 150g CSM)
Uni-Mould Tooling Resin (used with 4 layers of 450g CSM)

Uni-Mould Introduction & Application Guide Page 1 of 2

Easy Composites Ltd | Tel +44 (0)1782 454499 | www.easycomposites.co.uk | [email protected]
 Uni-Mould Introduction & Application Guide

Uni-Mould Tooling Resin Application

Finished Use
Composite moulds made from the Uni-Mould system can be used
for wet-lay, vacuum bagging and resin infusion. Moulds made from
Uni-Mould are 100% compatible with epoxy resin, polyester resin and
vinylester resin.

Polishing
The laminating technique for the Uni-Mould Tooling Resin is quite
different from conventional polyester laminating resins and it is
essential that you familiarise yourself with this technique and follow the
guidelines carefully in order for the resin to cure properly and result in
a successful mould.
Uni-Mould Tooling Resin is cured by its own exotherm and must reach
a temperature of 50-60°C during its cure in order to achieve its full
properties. In order for this to happen your workshop environment
needs to be between 18°C and 25°C and you must lay down a minimum
of 4 layers of 450gsm or resin-rich (4:1) CSM onto the back of the mould
in a single session.

Preparation Moulds made using Uni-Mould are highly polishable to a full gloss
and can easily be restored if they are subject to light scratches using a
In order to ensure that all the reinforcement can be laid down in a composites polishing compound (such as Mirka T10). After polishing,
single session it is important to prepare the resin and reinforcement in ensure a thorough re-application of release agent before use.
advance before starting to laminate.
Cut your 450gsm CSM to the right shapes for your mould, allowing for a Release Agent
minimum of 4 layers of mat. Once you have cut the mat, weigh it to see
how much CSM you will be using. Because Uni-Mould’s tooling gel coat is fully compatible with epoxy,
polyester and vinylester, a wide range of release agents (waxes and
Next, weigh out 4 times the weight of the glass in resin (Uni-Mould chemical release agents) should all result in a good release. Uni-Mould
Tooling Resin should be used at a typical 4:1 ratio or resin to glass) is tested and recommended for use with Easy-Lease Chemical Release
which means if you are using 5kgs of CSM to reinforce your mould you Agent which is universally suitable for all resin systems and processes.
should prepare 20kgs of resin.

Begin Laminating
When you are ready, catalyse the resin using MEKP catalyst at 0.75 – Disclaimer
1.25% (depending on the ambient temperature) and mix thoroughly.
This data is not to be used for specifications. Values listed are for typical
Working quickly, apply resin all over the mould and then add layers of properties and should not be considered minimum or maximum.
glass one at a time, wetting with plenty of resin (4:1 by weight) until you
have added all the layers of glass to the back of the mould. You should Our technical advice, whether verbal or in writing, is given in good faith
use the last of the prepared resin as you add the last layer of CSM. but Easy Composites Ltd gives no warranty; express or implied, and all
products are sold upon condition that purchasers will make their own
As the laminate starts to cure the temperature will rise to 50-60°C and tests to determine the quality and suitability of the product for their
the colour of the laminate will change from a mid brown to a light brown particular application and circumstances.
colour.
Easy Composites Ltd shall be in no way responsible for the proper
Allow the resin to cure fully for 24hrs. use and service of the product, nor for the safeguarding of personnel
or property, all of which is the duty of the user. Any information or
Post Curing suggestions are without warranty of any kind and purchasers are solely
responsible for any loss arising from the use of such information or
For ambient temperature use, a post cure of the mould is recommended,
suggestions. No information or suggestions given by us shall be deemed
but not required. If you intend to use the mould for higher temperature
to be a recommendation to use any product in conflict with any existing
curing or in-mould post curing of your parts then an elevated
patent rights.
temperature post cure is required.
Before using any of our products, users should familiarise themselves
Recommended post-cure for elevated temperature mould use:
with the relevant Technical and MSDS provided by Easy Composites Ltd.
10hrs at 60°C › 2hrs at 70°C › 2hrs at 80°C › 2hrs at 90°C

Easy Composites Ltd

Unit 39, Park Hall Business Village, Longton, Stoke on Trent, Staffordshire, ST3 5XA, United Kingdom.
Tel. +44 (0)1782 454499, Fax. +44 (0)1782 596868, Email [email protected], Web www.easycomposites.co.uk

Uni-Mould Introduction & Application Guide Page 2 of 2