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 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
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 | °C | 135 | |
| Pot life | Min. | ~17 – 20 | |
| Reaction temperature | °C | 120 – 130 | |
| Hardness | Shore D | ~±D86 | |
| Compressive strength at RT 20 °C / 100 °C | DIN 53454 | 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 53460 | °C | 180 |
| Shelf life at 16 °C to 22 °C | Months | ~18 | |
| Thermal expansion coefficient | DIN 53752 | 10-6*K-1 | 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 |
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| Step 1 |
| 40 % resin components, mixing ratio: comp. 1 : comp. 2 1 : 2 |
|
| Step 2 |
| 60 % Stir in 60 % filler, mixing ratio: resin : aluminium spray grit 1 : 1.5 |
|
| Step 3 |
| Vent 1 – 2 hrs. temperature must be between 19 °C – 22 °C |
|
| Step 4 |
| 3 % Stir in 3 % hardener powder |
|
| 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 |
Downloads
Product brochure: CASTING RESIN FOR THE THERMOFORMING PROCESS ALWA MOULD D
Calculation of a batch quantity ALWA MOULD D
Success story: VST WORKS
Success story: GWK KUHLMANN
Success story: DEALS & WHEELS