Recent years have seen more manufacturers across industries benefit from closed moulding processes. Making the change from open to closed moulding requires careful consideration, but the transition generally offers an array of worthwhile advantages.
Hand layup, also known as wet layup, is one of the most basic and least expensive composite processing methods. It is a manual open moulding process involving the application of reinforcement materials and resin into a single-sided mould.
The fibre material is placed into the mould (on top of gel coating to achieve a high-quality surface), and resin is applied by hand, with rollers or brushes. As it is a manual process, the quality of the final part is usually quite dependent on the skill of the individual processing it.
The hand layup method can be used to make a wide variety of parts, including custom, single-piece and intricately designed components where production flexibility is a priority. As curing occurs at room temperature and the production cycle is slow, hand layup is generally not preferred for high-volume projects.
Closed moulding methods are generally preferred for large-scale production. Here, the reinforcing materials are placed inside a sealed, double-sided mould cavity before resin is injected into the mould, with a vacuum or pressure applied to ensure proper distribution.
There are several different closed moulding methods, all with their own pros and cons.
Various industries are beginning to find increased success with the different closed moulding processes compared to traditional hand layup techniques.
One of the most obvious benefits of using closed moulding over hand layup or other open moulding techniques is the increased level of quality. As most closed moulding methods will use some form of automation, these processes can provide higher levels of consistency, strength, structural integrity and overall quality.
Closed moulds ensure you achieve a smooth finish on both sides of the part, reducing the need for post-processing work. The use of machinery and automation also leaves less room for human error, which is inevitable with manual processing methods like hand layup.
As closed moulding can give you better control over fibre placement and resin content, the whole process can become more precise, giving you high-performance, dimensionally accurate components, which is ideal for application in aerospace, marine and wind energy industries.
Another key feature of closed processes, like resin transfer moulding, is its potential for scalability. While suitable for small batch production, close moulding works particularly well for large-scale projects and at higher volumes.
The automated process, reduced requirements for manual labour and increased control mean that production cycles can be faster, again making it the preferred option for high production runs.
Increased resin flow control also means you can maximise material efficiency and reduce waste, using only what is required for each component. Closed moulding processes can be more sustainable and cost-effective than their open moulding counterparts.
Sealed moulds and closed systems have reduced VOC emissions, helping contribute to a cleaner and healthier work environment. moulds and closed systems have reduced VOC emissions, helping contribute to a cleaner and healthier work environment.
All of these closed moulding advantages paint a good picture of how beneficial it could be to update your processing methods.
Developing the right process for your needs will ultimately increase efficiency and quality, laying the foundation for ongoing development and long-term success.
Understanding the benefits of closed moulding is the first step when thinking about making the switch from hand layup processing. It’s also important to consider what kind of closed moulding system is right for your production needs – is RTM suitable, or is another method required?
Discussing your needs with composite specialists who can guide you through the complexities of closed moulding processes can prove invaluable, as they help develop tailored solutions that align with your business objectives.
Composite manufacturing process development services ensure you can establish exactly what you need and the practical steps in which it can be achieved. Appropriate material selection and tooling for closed moulding will be established at this stage.
Comprehensive training on new processes and machinery is also essential when making the move to closed moulding. Again, working closely with specialists to train your team and optimise systems will ensure a much smoother transition from open to closed moulding.
Here at Composite Integration, we’re dedicated to providing the best composite manufacturing tools, processes and expertise to ensure your projects return the best possible results.
No matter your requirements or industry, we’ll work with you to develop a custom solution that ticks all the boxes when it comes to quality, consistency and efficiency.
From providing advanced composite machinery to offering R&D services and training programmes, the Composite Integration team aims to revolutionise the approach to composite manufacturing to the benefit of all our customers.
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