Casting resin for the thermoforming process

In the following “ALWA MOULD D” (patent no. 2801463).

ALWA MOULD D consists of two resin components and an aluminium filler. The fast curing of the material allows to produce technologically highest quality moulds in just one day. As our material is very good castable, compact moulds of any desired volume can be made from our product, such as acrylic baths, boats, etc. (<1 kg – 2500 kg). In comparison to other materials (e.g., glass fibre reinforced plastic), the system is more temperature-resistant, allows castings without air bubbles and does not have to be post-cured. Furthermore, the finished mould is easy machinable (e.g., drilling, milling, grinding, planning, sawing, turning, etc.). ALWA MOULD D moulds can be modified with repair filler, so that a fresh view can be created at an early stage of a new design process and prototypes can be examined at short notice.

ALWA MOULD  D / ATLAS M 130 is characterized by the following advantages:

  • Fast curing in approx. 50 min.
  • Good castability
  • Cast without air inclusions
  • Good mechanical finishing
  • Post curing is unnecessary
  • High temperature resistance
  • Low linear shrinkage
  • Highly accurate mould surface reproduction
  • Easy casting of small and big quantities (1 kg – 2500 kg)

Productvideo ALWA MOULD D / ATLAS M130

Moulds made of ALWA MOULD D are resistant to temperatures of up to 135 °C, short term exposure of up to 180 °C is possible, taking into account the lower compressive strength of the mould due to the temperature. In order to control the temperature of the mould during the production process, copper pipes or heating systems can be included in the casting process. To ensure the same thermal expansion coefficient only aluminium and perforated aluminium sheets should be attached to the casting box as reinforcements, which are afterwards recast with casting resin. Instead of drilling time-consuming vacuum holes in the finished mould, steel wires with silicone hose can be applied to the pattern.

Characteristic  Norm Unit Value
Temperature resistance DIN 53462 / ISO 75 B °C 135
Pot life Min. ~17 – 20
Reaction temperature °C 120 -130
Hardness Shore D ~±D86
Compressive strength at RT 20 °C / 100 °C KN/cm² 8 – 9 / 7 – 8
Impact strength DIN 53453 J/n (KJ/m²) 3400 (3.5)
Viscosity of the mixture mPAS ~7,000
Specific density kg/l 1.7
Thermal conductivity DIN 1341 W/mk (Kcal/hm°C) ~1 (~0.86)
Linear shrinkage after the curing process (specimen 500 x 100 x 25 mm) % ~±0.1
Vicat softening temperature DIN 1341 °C 180
Shelf life at 16 °C to 22 °C Months ~18
Thermal expansion coefficient DIN 1341 °C 10-6/45

Work steps

Step 1 Step 2 Step 3 Step 4 Step 5
40 % resin components,
mixing ratio:
comp. 1 : comp. 2
1        :      2
Stir in 60 % filler,
mixing ratio:
resin : aluminium spray grit
1    :      1.5
Vent 1 – 2 hrs. temperature must be between  19 °C – 22 °C Stir in 3 % hardener powder casting
  alwa-mould-p-icon-tabelle    alwa-mould-p-icon-tabellealwa-mould-p-icon-tabelle    alwa-mould-p-icon-tabelle    alwa-mould-p-icon-tabelle
Step 1
40 % resin components, mixing ratio:
comp. 1 : comp. 2
1 : 2
alwa-mould-p-icon-tabelle
Step 2
60 % Stir in 60 % filler, mixing ratio:
resin : aluminium spray grit
1 : 1.5
alwa-mould-p-icon-tabellealwa-mould-p-icon-tabelle
Step 3
Vent 1 – 2 hrs. temperature must be between 19 °C – 22 °C
alwa-mould-p-icon-tabelle
Step 4
3 % Stir in 3 % hardener powder
alwa-mould-p-icon-tabelle
Step 5
casting

ALWA MOULD D System:

ALWA MOULD D, component 1 5 kg / 25 kg / 50 kg / 200 kg art. no. 6000…
ALWA MOULD D, component 2 5 kg / 25 kg / 50 kg / 200 kg art. no. 6001…
Aluminium spray grit < 65 µm 25 kg art. no 4065025
Hardener powder  1 kg art. no. 5100001

Tools:

ALWA ACRYLIC SEALER art. no. 9535000
ALWA SURFACE TENSION REMOVER art. no. 9500000
ALWA RELEASE LACQUER art. no. 9510000
ALWA RELEASE SPRAY art. no. 9515000
ALWA REPAIR FILLER art. no. 3050001
ALWA PU FOAM, comp. A art. no. 9700005
ALWA PU FOAM, comp. B art. no. 9701006
SILICONE TUBES art. no. 9205000
STEEL WIRES art. no. 9211000
ALUMINIUM PERFORATED STEEL art. no. 9213000

Mixers and drills :

SPECIAL MIXERS up to 1 litre art. no. 9110000
up to 10 litres art. no. 9120000
up to 25 litres art. no. 9130000
up to 75 litres art. no. 9140000
DRILLS 0,6 x 30 x 60 mm art. no. 9006000
0,8 x 60 x 100 mm art. no. 9008000
1,0 x 60 x 100 mm art. no. 9010000
1,5 x 110 x 150 mm art. no. 9015000
here

Application

Information about the application
here