Specifications

For Encapsulating Electronic Parts Premix the Part A and Part B at a 4:1 mix ratio by weight or volume and mix as demonstrated in the instructional video. Pre-arrange the wire leads to the desired position and secure. insure that the component housing can withstand the cure temperature to be encapsulated. Pour or dispense only from one corner of the component casing and allow the material to completely flow and fill throughout the casing. This technique will reduce voids and air entrapment. Allow the resin to gel or cure at room temperature for at least 4 hours or until dry to the touch. Place the component in an oven and post cure for 3 Hours At 130˚C.Use these standards and conversion to determine yield and usage cost1 GALLON = 231 CUBIC INCHES1 GALLON OF RESIN CAN COVERS 1608 SQUARE FEET1 MIL OR 0.001 INCH CURED COATING THICKNESS1 GALLON OF RESIN IS 128 OUNCES1 GALLON OF MIXED EPOXY RESIN IS 9.23 POUNDS1 GALLON OF RESIN IS 3.7854 LITERSMAX HTE used as an impregnating resin for fiberglass and carbon fiber. Carbon Fiber McLaren MP4-12c High-Temperature Resistant Engine Vent -Typical Temperature Exposure Is 350°F COMPOSITE FABRICATING BASIC GUIDELINES By definition, a fabricated COMPOSITE material is a manufactured collection of two or more ingredients or products intentionally combined to form a new homogeneous material that is defined by its performance that should uniquely greater than the sum of its individual parts. This process of fabrication is also defined as a SYNERGISTIC COMPOSITION. COMPOSITE MATERIAL COMPOSITIONREINFORCING FABRIC & IMPREGNATING RESIN PLUS 'ENGINEERED PROCESS'EQUALSCOMPOSITE LAMINATE WITH THE BEST WEIGHT TO STRENGTH PERFORMANCE With respect to the raw materials selection -fabric and resin, the fabricating process and the and curing and test validation of composite part, these aspects must be carefully considered and in the engineering phase of the composite. Step One: Fabric SelectionTYPES OF FABRIC WEAVE STYLE AND SURFACE FINISHING FOR RESIN TYPE COMPATIBILITYFabrics are generally considered ”balanced” if the breaking strength is within 15% warp to fill and are best in bias applications on lightweight structures.“Unbalanced” fabrics are excellent when a greater load is required one direction and a lesser load in the perpendicular direction. Tow: The bundle of individual carbon filaments used to weave carbon fabric. 50k tow means there are 48-50,000 carbon filaments in the tow. Smaller tow i.e. 12k, 6k, 3k and 1k are obtained by dividing the 50k tow into smaller bundles.Thread Count: The number of threads (tow in carbon and yarn in Aramid) per inch. The first number will be the warp count and the second will be the fill count. Fill: The threads that run the width of the roll or bolt and perpendicular to the warp threads. Warp: The threads that run the length of the roll or bolt and perpendicular to the fill threads. Finish: The chemical treatment to fiberglass making it compatible with resin systems, therefore improving the bond between the fiber and the resin. Finishing fiberglass typically decreases the fiber strength by as much as 50%. Both Silane and Volan finishes are epoxy compatible. Historically, Volan has been considered a softer finish for a more pliable fabric, but recent advances have yielded some excellent soft Silane finishes.Thickness: Measured in fractions of an inch. The thicker the fabric the more resin required to fill the weave to obtain a surface-smooth finished part.Weaves:Plain weave means the warp and fill threads cross alternately. This is the most common weave.4 Harness (4 HS Satin or crowfoot) weave means the fill thread floats over three warp threads, then under one warp thread. This weave is more pliable than the plain weave, therefore conforms to complex curves more easily.8 Harness (8 HS Satin) weave means the fill thread floats over seven warp threads, then under one warp thread. This weave is the most pliable of the standard fiberglass weaves.2 x 2 Twill weave means the fill thread floats over two warp threads, then fewer than two warp threads. This weave is found most commonly in carbon fabrics and is more pliable than plain weave.Most fabrics are stronger in the warp than the fill because higher tension is placed on the warp fiber keeping it straighter during the weaving process.Rare exceptions occur when a larger, therefore stronger thread is used in the fill direction than the warp direction. PLAIN WEAVEIs a very simple weave pattern and the most common style. The warp and fill yarns are interlaced over and under each other in alternating fashion. Plain weave provides good stability, porosity and the least yarn slippage for a given yarn count. 8 HARNESS SATIN WEAVEThe eight-harness satin is similar to the four-harness satin except that one filling yarn floats over seven warp yarns and under one.This is a very pliable weave and is used for forming over curved surfaces. 4 HARNESS SATIN WEAVEThe four-harness satin weave is more pliable than the plain weave and is easier to conform to curved surfaces typical in reinforced plastics. In this weave pattern, there is a three by one interfacing where a filling yarn floats over three warp yarns and under one. 2x2 TWILL WEAVETwill weave is more pliable than the plain weave and has better drivability while maintaining more fabric stability than a four or eight harness satin weave. The weave pattern is characterized by a diagonal rib created by one warp yarn floating over at least two filling yarns. SATIN WEAVE TYPE CONFORMITY UNTO CURVED SHAPES Plain Weaves, Bi-axial, Unidirectional Styles For Directional High Strength Parts Use this weave style cloth when high strength parts are desired.It is ideal for reinforcement, mold making, aircraft and auto parts tooling, marine, and other composite lightweight applications.7544 Fiberglass - YouTube FIBERGLASS FINISHING FOR RESIN COMPATIBILITYFinishing Cross Reference And Resin Type Compatibility RESIN COMPATIBILITYBurlington IndustriesClarkSchwebelJ.P StevensUniglass IndustriesEpoxy, PolyesterVOLAN AVOLAN AVOLAN AVOLAN AEpoxy, PolyesterI-550CS-550S-550UM-550Phenolic, MelamineI-588A1100A1100A1100Epoxy, PolyimideI-589Z6040S-920UM-675EpoxyI-399CS-272AS-935UM-702Epoxy CS-307 UM-718Epoxy CS-344 UM-724Silicone112112 n-pH (neutral pH) AVAILABLE FIBERGLASS, CARBON FIBER, AND KEVLAR FABRICSHEXCEL 120 1.5-OUNCE FIBERGLASS PLAIN WEAVE 5 YARDShttps://www.ebay.com/itm/222623985867HEXCEL 120 1.5-OUNCE FIBERGLASS PLAIN WEAVE 10 YARDShttps://www.ebay.com/itm/311946399588HEXCEL 7532 7-OUNCE FIBERGLASS PLAIN WEAVE 5 YARDShttps://www.ebay.com/itm/222624899999HEXCEL 7500 10 OUNCE FIBERGLASS PLAIN WEAVE 3 YARDShttps://www.ebay.com/itm/222624968104HEXCEL 7500 10 OUNCE FIBERGLASS PLAIN WEAVE 5 YARDShttps://www.ebay.com/itm/311946460378HEXCEL 3582 14 OUNCE FIBERGLASS SATIN WEAVE 5 YARDShttps://www.ebay.com/itm/312023587290HEXCEL 3582 14 OUNCE FIBERGLASS SATIN WEAVE 10 YARDShttps://www.ebay.com/itm/222753506374HEXCEL 1584 26 OUNCE FIBERGLASS SATIN WEAVE 3 YARDShttps://www.ebay.com/itm/311947365010HEXCEL 1584 26 OUNCE FIBERGLASS SATIN WEAVE 5 YARDShttps://www.ebay.com/itm/222629157570FIBERGLASS 45+/45- DOUBLE BIAS 3 YARDShttps://www.ebay.com/itm/311947299244 CARBON FIBER FABRIC 3K 2x2 TWILL WEAVE 6 OZ. 3 YARDShttps://www.ebay.com/itm/311947275431CARBON FIBER FABRIC 3K PLAIN WEAVE 6 OZ 3 YARDShttps://www.ebay.com/itm /311947292012 KEVLAR 49 HEXCEL 351 PLAIN WEAVE FABRIC 2.2 OZhttps://www.ebay.com/itm/222623951106 Step Two: Choose The Best Epoxy Resin System For The ApplicationThe epoxy resin used in fabricating a laminate will dictate how the FRP will perform when load or pressure is implied on the part.To choose the proper resin system, consider the following factors that is crucial to a laminate's performance.SIZE AND CONFIGURATION OF THE PART(NUMBER OF PLIES AND CONTOURED, FLAT OR PROFILED)CONSOLIDATING FORCE(FREE STANDING DRY OR HAND LAY-UP, VACUUM BAG OR PLATEN PRESS CURING)CURING CAPABILITIES(HEAT CURED OR ROOM TEMPERATURE CURED)LOAD PARAMETERS(SHEARING FORCE, TORSIONAL AND DIRECTIONAL LOAD, BEAM STRENGTH)ENVIRONMENTAL EXPOSUREThe principal role of the resin is to bind the fabric into a homogeneous rigid substrate(OPERATING TEMPERATURE, AMBIENT CONDITIONS, CHEMICAL EXPOSURE, CYCLIC FORCE LOADING)MATERIAL AND PRODUCTION COST(BUYING IN BULK WILL ALWAYS PROVIDE THE BEST OVERALL COSTS) These factors will dictate the design and the composition of the part and must be carefully considered during the design and engineering phase of the fabrication. TOP SELLING IMPREGNATING RESIN SYSTEM MAX BOND LOW VISCOSITY A/B Marine Grade Boat Building Resin System, Fiberglassing/Impregnating, Water Resistance, Cured Structural StrengthMAX BOND LOW VISCOSITY 32-Ounce kithttps://www.ebay.com/itm/311947109148MAX BOND LOW VISCOSITY 64-Ounce Kithttps://www.ebay.com/itm/311947125422MAX BOND LOW VISCOSITY 1-Gallon Kithttps://www.ebay.com/itm/311947117608MAX BOND LOW VISCOSITY 2-Gallon kithttps://www.ebay.com/itm/311946370391MAX BOND LOW VISCOSITY 10-Gallon Kithttps://www.ebay.com/itm/222624960548MAX 1618 A/B Crystal Clear, High Strength, Lowest Viscosity (Thin), Durability & Toughness, Excellent Wood Working ResinMAX 1618 A/B 48-Ounce Kithttps://www.ebay.com/itm/222627258390MAX 1618 A/B 3/4-Gallon Kithttps://www.ebay.com/itm/222625113128MAX 1618 A/B 3/4-Gallon Kithttps://www.ebay.com/itm/222627258390MAX 1618 A/B 1.5-Gallon Kithttps://www.ebay.com/itm/311946441558MAX CLR A/B Water Clear Transparency, Chemical Resistance, FDA Compliant For Food Contact, High Impact, Low ViscosityMAX CLR A/B 24-Ounce Kithttps://www.ebay.com/itm/222623963194MAX CLR A/B 48-Ounce Kithttps://www.ebay.com/itm/311947320101MAX CLR A/B 96-Ounce Kithttps://www.ebay.com/itm/222625329068MAX CLR A/B 96-Ounce Kithttps://www.ebay.com/itm/222625338230MAX CLR A/B 1.5-Gallon Kithttps://www.ebay.com/itm/222626972426MAX GRE A/B GASOLINE RESISTANT EPOXY RESIN Resistant To Gasoline/E85 Blend, Acids & Bases, Sealing, Coating, Impregnating ResinMAX GRE A/B 48-Ounce Kithttps://www.ebay.com/itm/311946473553MAX GRE A/B 96-Ounce Kithttps://www.ebay.com/itm/311947247402MAX HTE A/B HIGH-TEMPERATURE EPOXY Heat Cured Resin System For Temperature Resistant Bonding, Electronic Potting, Coating, BondingMAX HTE A/B 80-Ounce Kithttps://www.ebay.com/itm/222624247814MAX HTE A/B 40-Ounce Kithttps://www.ebay.com/itm/222624236832 Step Three: Proper Lay-Up Technique -Putting It All TogetherPre-lay-up notesLay out the fabric and pre-cut to size and set asideAvoid distorting the weave pattern as much as possibleFor fiberglass molding, ensure the mold is clean and adequate mold release is usedView our video presentation above "MAX EPOXY RESIN MIXING TECHNIQUE"Mix the resin only when all needed materials and implements needed are ready and within reachMix the proper amount of resin needed and be accurate proportioning the resin and curing agent. Adding more curing agent than the recommended mix ratio will not promote a faster cure. Over saturation or starving the fiberglass or any composite fabric will yield poor mechanical performance. When mechanical load or pressure is applied to the composite laminate, the physical strength of the fabric should bear the stress and not the resin. If the laminate is over saturated with the resin it will most likely to fracture or shatter instead of rebounding and resist damage. Don’t how much resin to use to go with the fiberglass?A good rule of thumb is to maintain a minimum of 30 to 35% resin content by weight, this is the optimum ratio used in high-performance prepreg (or pre-impregnated fabrics) typically used in aerospace and high-performance structural application. For general hand lay-ups, calculate using 60% fabric weight to 40% resin weight as a safety factor. This will ensure that the fabricated laminate will be below 40% resin content depending on the waste factor accrued during fabrication. Place the entire pre-cut fiberglass to be used on a digital scale to determine the fabric to resin weight ratio.Measuring by weight will ensure accurate composite fabrication and repeatability, rather than using OSY data.THE USE OF A WEIGHING SCALE IS HIGHLY RECOMMENDED Purchase this scale with any of our product offering and the shipping cost of the scale is free. https://www.ebay.com/itm/222630300203A good rule of thumb is to maintain a minimum of 30 to 35% resin content by weight. This is the optimum ratio used in high-performance prepreg (or pre-impregnated fabrics) typically used in aerospace and high-performance structural application. For general hand lay-ups, calculate using 60% fabric weight to 40% resin weight as a safety factor. This will ensure that the fabricated laminate will be below 40% resin content depending on the waste factor accrued during fabrication.Place the entire pre-cut fiberglass to be used on a digital scale to determine the fabric to resin weight ratio. Measuring by weight will ensure accurate composite fabrication and repeatability, rather than using OSY data. 1 ounce per square yard is equal to 28.35 grams 1 square yard equals to 1296 square inches (36 inches x 36 inches)FOR EXAMPLE 1 yard of 8-ounces per square yard (OSY) fabric weighs 226 grams 1 yard of 10-ounces per square yard (OSY) fabric weighs 283 grams Ounces per square yard or OSY is also known as aerial weight, which is the most common unit of measurement for composite fabrics.To determine how much resin is needed to adequately impregnate the fiberglass, use the following equation: (Total Weight of Fabric divided by 60%)X( 40%)= weight of mixed resin needed MASTER EQUATION (fw/60%)x(40%)=rnFOR EXAMPLE 1 SQUARE YARD OF 8-OSY FIBERGLASS FABRIC WEIGHS 226 GRAMS (226 grams of dry fiberglass / 60%) X 40% = 150.66 grams of resin needed So for every square yard of 8-ounce fabric, it will need 150.66 grams of mixed resin. Computing For Resin And Curing Agent Amount 150.66 grams of resin needed MIX RATIO OF RESIN SYSTEM IS 2:1 OR 50 PHR (per hundred resin) 2 = 66.67% (2/3) + 1 = 33.33%(1/3) (2+1)=3 or (66.67%+33.33%)=100% or (2/3+1/3)= 3/3 150.66 x 66.67%= 100.45 grams of Part A RESIN 150.66 x 33.33%= 50.21 grams of Part B CURING AGENT 100.45 + 50.21 = 150.66 A/B MIXTUREGENERAL LAY-UP PROCEDURE Apply the mixed resin onto the surface and then lay the fabric and allow the resin to saturate through the fabric.NOT THE OTHER WAY AROUNDThis is one of the most common processing error that yields sub-standard laminates. By laying the fiberglass onto a layer of the prepared resin, fewer air bubbles are entrapped during the wetting-out stage. Air is pushed up and outwards instead of forcing the resin through the fabric which will entrap air bubbles. This technique will displace air pockets unhindered and uniformly disperse the impregnating resin throughout the fiberglass.HAND LAY-UP TECHNIQUE Eliminating air entrapment or void porosity in an epoxy/fiberglass lay-up processFiberglass Hand Lay Up For Canoe and Kayak Building- Cedar Strip Kayak Fiberglassing - YouTubeVideo will open in a new windowBasic Hand Lay-up FiberglassingVideo will open in a new windowVACUUM BAGGING PROCESS For performance critical application used in aerospace vehicles, composite framing for automotive vehicles and marine vessels,a process called 'Vacuum Bagging' is employed to ensure the complete consolidation of every layer of fabric. The entire tooling and lay-up are encased in an airtight envelope or bagging and a high-efficiency vacuum pump is used to draw out the air within the vacuum bag to create a negative atmospheric pressure.Once a full vacuum (29.9 Inches of Mercury) is achieved, the negative pressure applies a compacting force of 14.4 pounds per square inch (maximum vacuum pressure at sea level) is applied to the vacuum bag transferring the force to the entire surface area of the laminate. Vacuum pressure is maintained until the resin cures to a solid. For room temperature curing resin system, the vacuum pump is left in operation for a minimum of 18 hours.External heat can be applied to the entire lay-up, thus accelerating the cure of the resin system. The vacuum force also removes any entrapped air bubble between the layers of fabric and eliminate what is called, porosity or air voids.Porosity within a laminate creates weak spots in the structure that can be the source of mechanical failure when force or load is applied to the laminate. The standard atmosphere (symbol: atm) is a unit of pressure defined as 101325 Pa (1.01325 bar), equivalent to 760 mm Mercury or 29.92 inches Mercury or14.696 pounds per square inch of pressure. FiberglaSs And Carbon Fiber Vacuum Bagging and Flat Panel Laminate - YouTubeVideo will open in a new window AUTOCLAVE CURING PROCESS Autoclave curing processing is the most common method used in large-scale production of composite products.The aerospace industry, which includes space exploration rockets and vehicles, satellites, and military airplane utilizes this composite fabrication process due to the critical nature of the application.The mechanical demands of the composite are often pushed to the upper limits and autoclaved process yields composites with the best weight to strength ratio.BASIC OPERATION OF THE AUTOCLAVE PROCESS In the autoclave process, high pressure and heat are applied to the part through the autoclave atmosphere,with a vacuum bag used to apply additional pressure and protect the laminate from the autoclave gases. The cure cycle for a specific application is usually determined empirically and, as a result, several cure cycles may be developed for a single material system,to account for differences in laminate thickness or to optimize particular properties in the cured part.The typical autoclave cure cycle is a two-step process.First, vacuum and pressure are applied while the temperature is ramped up to an intermediate level and held there for a short period of time.The heat reduces the resin viscosity, allowing it to flow and making it easier for trapped air and volatiles to escape.The resin also begins wetting the fibers at this stage. In the second ramp up, the temperature is raised to the final cure temperature and held for a sufficient length of time to complete the cure reaction.During this step, the viscosity continues to drop, but preset temperature ramp rates and hold times then stabilize viscosity at a level that permits adequate consolidation and fiber wetting,while avoiding excessive flow and subsequent resin starvation. These control factors also slow the reaction rate, which prevents excessive heat generation from the exothermic polymerization process.Upon completion, the cured mechanical performance of the composite is often much stronger and lighter compared to a hand lay-up, or vacuum bagged composite laminate. VACUUM INFUSION PROCESSVacuum Infusion Process is also known in the composites industry as Vacuum Assisted Resin Transfer Molding or VARTM.Similar to the Vacuum Bagging Process where the negative pressure is used to apply consolidation force to the laminate while the resin cures, the resin is infused into the fabric lay-up by sucking the impregnating resin and thus forming the composite laminate.The VARTM Process produces parts that require less secondary steps, such as trimming, polishing or grinding with excellent mechanical properties. However, the vacuum infusion requires more additional or supplemental related equipment and expendable materials. So the pros and cons of each presented composite fabrication process should be carefully determined to suit the user's capabilities and needs. Please view the following video demonstration which explains the process of Vacuum Infusion or VARTM process.MAX 1618 A/B VACUUM ASSISTED RESIN TRANSFER MOLDING PROCESSCARBON FIBER VACUUM INFUSION WITH EPOXY RESIN - VACUUM BAGGING WITH MAX 1618 EPOXY RESIN - YouTubeVideo will open in a new windowStep Four: Proper CuringMAX EPOXY RESIN SYSTEM product line is resistant to amine-blush, however, it is recommended not to mix any resin systems in high humidity conditions, greater than 60%.Review the PHYSICAL PROPERTIES TABLE for the proper cure conditions Review the published data and information for proper usage, application, and general safety information. Our expert staff of engineers is always available for consultation and assistance. Allow the lay-up to cure for a minimum of 24 to 36 hours before handling.Optimum cured properties can take up to 7 days depending on the ambient cure condition. The ideal temperature cure condition of most room temperature epoxy resin is 22°C - 27°C at 20% relative humidity.Higher ambient curing temperatures will promote faster polymerization and development of cured mechanical properties. Improving mechanical performance via post heat cure A short heat post cure will further improve the mechanical performance of most epoxy resins. Allow the applied resin system to cure at room temperature until for 18 to 24 hours and if possible,expose heat cure it in an oven or other sources of radiant heat (220°F to 250°F) for 45 minute to an hour.You can also expose it to direct sunlight but place a dark colored cover, such as a plastic tarp or cardboard to protect it from ultraviolet exposure.In general room temperature cured epoxy resin has a maximum operating temperature of 160°F or lower.A short heat post cure will ensure that the mixed epoxy system is fully cured, especially for room temperature cure system that can take up to 7 days to achieve 100% cureSome darkening or yellowing of the epoxy resin may occur if overexposed to high temperature (>250°F). AMINE BLUSHThe affinity of an amine compound (curing agent) to moisture and carbon dioxide creates a carbonate compound and forms what is called amine blush.Amine blush is a wax-like layer that forms as most epoxies cure. If the epoxy system is cured in extreme humidity (>70%).It will be seen as a white and waxy layer that must be removed by physical sanding of the surface followed by an acetone wipe. TESTING THE COMPOSITEDETERMINATION OF THE FABRIC-RESIN RATIO TESTING FABRIC TO RESIN RATIO VIA RESIN BURN OUT - YouTubeVideo will open in a new windowULTIMATE COMPRESSIVE STRENGTH ULTIMATE COMPRESSIVE STRENGTH TEST OF FIBERGLASS LAMINATE TOOLING BOARD. - YouTubeVideo will open in a new window6500 Pounds To Failure / 0.498 Square Inch = 13,052 PSI Maximum Compressive StrengthSPECIMEN EXAMINATION AFTER COMPRESSION TEST - YouTubeVideo will open in a new window************************************************************DON'T FORGET OUR EPOXY MIXING KITClick The Link To Add To Order https://www.ebay.com/itm/222623932456EVERYTHING YOU NEED TO MEASURE, MIX, DISPENSE OR APPLY Proportioning the correct amount is equally as important to attain the intended cured properties of the resin system.The container in which the epoxy and curing agent is mixed is an important consideration when mixing an epoxy resin system. The container must withstand the tenacity of the chemical and must be free of contamination.Most epoxy curing agent has a degree of corrosivity, as a general practice, protective gloves should be worn when handling chemicals of the same nature. MIXING KIT CONTENTS 1 Each Digital Scale -Durable, Accurate Up To 2000.0 Grams 4 Each 32-ounce (1 Quart) Clear HDPE Plastic Mix Cups4 Each 16-ounce (1 Pint) Clear HDPE Plastic Mix CupsOne Size Fits All Powder-Free Latex Gloves 2 Each Graduated SyringesWooden Stir SticksFoam Brush IMPORTANT NOTICEYour purchase constitutes the acceptance of this disclaimer. Please review before purchasing this product.The user should thoroughly test any proposed use of this product and independently conclude the satisfactory performance in the application. Likewise, if the manner in which this product is used requires government approval or clearance, the user must obtain said approval.The information contained herein is based on data believed to be accurate at the time of publication. Data and parameters cited have been obtained through published information, PolymerProducts and Polymer Composites Inc. laboratories using materials under controlled conditions. Data of this type should not be used for a specification for fabrication and design. It is the user's responsibility to determine this Composites fitness for use.There is no warranty of merchantability for fitness of use, nor any other express implied warranty. The user's exclusive remedy and the manufacturer's liability are limited to refund of the purchase price or replacement of the product within the agreed warranty period. PolymerProducts and its direct representative will not be liable for incidental or consequential damages of any kind. Determination of the suitability of any kind of information or product for the use contemplated by the user, the manner of that use and whether there is any infringement of patents is the sole liability of the user.

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