b'STAGE1 Plug PreparationThe first step in fibreglass mould making is to make a plug.If the mould is to see high temperatures and a post cure is The plug for a fibreglass or composite mould is usually an exactnecessary on the plug then your selection of materials will change. representation of the finished part, and can be an actual part or aIn this brochure we focus on making tools that are used extensively mock up of a part. In planning for the mould certain factors mustfor producing Polyester Resin hand lay, spray lay up, closed mould be taken into consideration; surface finish, draft angles, undercuts,or other RTM andresin infused parts. Plugs made from scratch can and method of production. A composite mould that is going tobe done from a wide variety of materials using a wide variety of be used for vacuum infusion or closed-moulding processes willmethods. There are many examples of making a plug from scratch require large flanges. Parts that are undercut or have negative draftand taking it all the way through making a mould. From a foam will need to be done in two part moulds for them to be able to becore, to plywood to make the flanges, and glassed over to provide extracted from the mould. Composite moulds that are designeda stable surface to fair over. You can use MDF to make plugs, high to be used with carbon fibre parts often need to be made out ofdensity foam, polystyrene, body filler, and other materials. carbon fibre in order to match the coefficient of thermal expansion,For large parts often a framework is built and then layered with especially if during the moulding process the part and mould willfoam, fibreglass, and body filler before priming and finishing.be heated to cure and then cooled to demould, i.e. prepreg parts. Forming the Plug1:Machine the chosen base (Polystyrene, Polyurethane,Timber etc).2:Apply 2 layers of the Resin (Norester 854) using 300gpowder bound mat. Laminate 10-15cm wider than the4plug. Allow to cure for 24hrs before applyingsprayable putty NCL 809 D605 or extrudableputty NCL 815. Spray with a Graco type machine (pump ratio 20:1) Use several thin passes until you achieve 5-6mm .3Final dimensions for CNC machining should be 8-12 mm.3:After machining apply Nord 230BV primer (several finepasses 450-600 microns) Then sandto a smooth finish. 24:Spray several coats of Nord Lacquer 210 to achieve ahigh gloss finish.Then sand with a fine paper. Finally you can then compound1the lacquer using Roar 900 and 910 polishing compound with a machine polisher.PRODUCT DESCRIPTION APPLICATIONNorester RMTooling Resin based on polyester resin,A low cost system. 2.5 : 1 Resin to Glass. GC210 PRIMER POLISH FOR GLOSS FINISH1000/50 especially formulated for mould making.Ideal for low volume cycle moulds. Once the plug is prepared and de-greased usingWet and dry your plug to the required standard and NORESTER 1000/50 is filled and pre-accelerated. TEK-KOTE Mould Cleaner, Spray GC210 Primer togloss finish, polish with mop and Roar 900 and 910 required thickness. cutting paste to level required for production needs.Norester RMTooling Resin formulated from an unsaturatedExtensively used in the Marine industry. 4 : 1 Resin to glass.2000/50 polyester resin. It is filled, promoted andApply min thickness of 8mm (2 layers) for machining.pre-accelerated. Formulated for mould making. Norester RMTooling Resin based on polyester resin forA rapid tooling resin with good surface appearance. Good curing.2550 the production of composite moulds with lowGood mouldability, and fast wet out, resin to glass ratio 2.5 : 1 Creates shrinkage. It is a product ready to use, filled andLighter moulds with better mechanicals properties hence lower tooling pre accelerated resin costs. Superior mechanical properties due to a glass content approximately 28% higher than with conventional tooling resins.Norester RMVinyl Ester Tooling Resin especially formulatedDesigned to polymerize at room temperature following addition of 3000 for producing composite moulds for applicationsnormal MEKP catalysts.Resin pre-accelerated and promoted, permits where high thermal and chemical resistance area fast curing and a rapid manufacture of moulds.An easy to use required product with low shrinkage hence high surface finish of the finished mould/parts.Fast build up of Barcol hardness. Improvement of the mould rigidity and low cost of mould production. Low exotherm curing system.Low viscosity.'