FRP Mould and Moulding for the benefit of Amusement and Water Park, IAC, Manufacturers and Users

“FRP – A Winning Formula”
for Amusement Park Manufacturers
and Users
By
Dr. Chaitanya Shah
(Mechemco Group)

Today’s Journey
• Introduction to FRP + Features and Benefits of FRP
• Safety in FRP Shop - Raw Materials Storage and
Handling
• Suitable Materials for FRP Production
• FRP Moulds –Key to Success
• FRP Manufacturing – Good Manufacturing Practices
• Showcasing – FRP Moulding
• New Trends in Materials and Processes
• Q & A

What Is FRP
• “FRP” is a acronym for
“Fibre Reinforced Polymer”
• Also used for Fibre Reinforced Polyester /
Fibre Rinforced Plastic
• We also used GRP – a subclass of Glass
Reinforced Polyester
Technically, FRP is a Composite Materials
with Fibrous Reinforcement in a Polymer
Matrix

FRP – A Wonder Material of Construction
• It is used in place of traditionally used
Structural Materials, viz., Metals like,
Steel & Aluminum; Wood; Concrete; etc.
• Produced using variety of Techniques
meeting best of Aesthetics and
Performance in Service Life
• Popular in Applications where:
Corrosion, Light Weighting, Aesthetics
and Variety of Shapes and Sizes, Fast
Track Design Board to Application is in
Demand

Benefits of FRP – From Amusement
Industry Perspective
• Light Weight with Optimum Stiffness and Specific Strength Range
• Single Piece, Complex Shape and Size
• Corrosion and Weather Resistant
• Easy to Tailor Design, Manufacture and Deliver in Short Time
Line
• Built-in Excellent Aesthetics and Performance – Real Value for
Money
• Easy Repair and Maintenance – Operational Cost Reduction
• Excellent Returns on Investment
• No Pilferage or Stealing (No Resale Value)

How is FRP Made?
• Creating a Composite Material using Fibrous
Reinforcements in Polymer Matrix material
• Addition of Specialty Additives and Performance
Additives to tailor unique requirement at the time of
Producing the FRP product
• Processing Methods include - Hand Lay-up, Spray-up,
RTM, LRTM, ULRTM, Infusion, Compression Moulding,
Pultrusion, Filament Winding etc.

The Good, The Bad & The Ugly of FRP
Quality and Performance Define the position of FRP Parts
against other Competing Materials – Specially with Respect to
Life Cycle Assessment Cost
• The Good as in Complex Shape and Aesthetics, Light weight
structure, Corrosion and Weather Resistance
• The Bad as difficult to Recycle and Disposal at End of Life
• The Ugly as in when it catches Fire!..

Safety in FRP Shop –
Raw Materials Storage and Handling

9
Safety – Reference is MSDS
• MSDS Give information on
• Guidelines for safety
• Handling Guidelines
• First aid measures
• Handling accidents and spills
• Fire Fighting Measures
• Storage and Transportation

10
Safety – Use Details in MSDS
• MSDS Give information on
• Potential Hazards
• Toxicology
• Human
• Animal
• Aquatic
• Fire Hazard
• Reactivity Hazard
• Environmental Hazards

11
Safety – Understand HMIS Codes

12
Safety – Resins/Gel coats
• Major Hazardous component –
Styrene
• Highly Flammable
• Keep away from ignition sources
• Use carbon dioxide, foam, dry
chemical or water fog to extinguish.
• Avoid Direct contact to the skin/eye
• Avoid Direct Inhalation

13
Safety – PPE – for Resin and Gelcoat
RESPIRATORY PROTECTION : In case of insufficient ventilation wear suitable
respiratory equipment
VENTILATION : Mechanical ventilation and local exhaust
OTHER PROTECTIVE
EQUIPMENT
a) Hands Protection : PVC or other plastic material gloves
b) Eye Protection : Splash Proof Goggles / Face Shield
c) Skin / Body Protection : Chemical Resistant Apron, Protective Suit,
Safety Shoes / Boots

14
Safety – Managing Spills and Leaks
• Spills/Leaks
• Eliminate all ignition sources.
• Prevent entry into sewers, drains or confined
areas.
• Absorb with an inert material and place in an
appropriate waste disposal container.
• Disposal Incinerate or land-fill in accordance
with local pollution regulation and ordinance.

Storage and Handling of Curing
Additives
• Promoter – Tertiary Amine Solution in Styrene Monomer
• Flammable and Reactive Substance, risk of polymerizing when exposed to direct heat
/ sunlight – must be stored in cool and dark place in original packing
• Accelerator – Cobalt Octoate Solution in Styrene Compatible Solvent
• Flammable and violently Reactive Substance when come in direct contact with
Peroxides – must be stored separately and away from Peroxide in Original Packing
• Catalyst – Methyl Ethyl Ketone Peroxide (MEKP) Dissolved in suitable
Stabilizing Solvent and Additives
• Flammable and Explosive when storage temperature goes beyond SADT value
mentioned in the Data Sheet / MSDS – must be stored in well ventilated place, cool,
and dark place, away from direct contact with Accelerator, in Original Packing

16
Safety- Curing Additives
• Promoter 
• Accelerator 
• Catalyst 

17
Safety – Curing Additives
Promoter - N, N’ Dimethyl Aniline
(or any other Promoter)
• Do not breath/inhale vapors
• Keep in closed containers in cool, well ventilated
place
• SMALL FIRE: Use DRY chemical powder. LARGE
FIRE: Use water spray, fog or foam. Do not use water
jet.

18
Accelerator - Cobalt Octoate Solution
(or any other Accelerator)
• Keep in closed containers in cool, well ventilated place
• SMALL FIRE: Use DRY chemical powder.
• LARGE FIRE: Use water spray, fog or foam. Do not use
water jet.

19
Catalyst - Methyl Ethyl Ketone Peroxide
(or any other Catalyst)
• SMALL FIRE: Use DRY chemical powder.
• LARGE FIRE: Use water spray, fog or foam.
• Vapors may form explosive mixtures with air.
• Do not use water jet.

20
Safety - Handling of Curing Additives
• Never allow Catalyst and Accelerator
to come in direct contact with each.
• Use Separate
Containers/Pipettes/Bottles/Measuring
cylinders for each
Direct Contact

21
Fire Fighting Measures - Flammable
Liquids
• Do not use water jet. (as they may spread the
fire)
• SMALL FIRE: Use DRY chemical powder,
CO2, sand.
• LARGE FIRE: Use Water Spray, Foam or Fog
• After Extinguishing, apply water to prevent
reigniting.

22
Fire Fighting Measures - Flammable
Liquids (cont…)
• Do not inhale fumes in case of fire
• After a fire, ventilate thoroughly the area and
soak with water, clean the walls and metallic
surfaces.

23
Safety – Handling of spills
• In Case of Spills
• Eliminate all ignition sources.
• Absorb with an inert material and place in
an appropriate waste disposal container.
• Keep contents moist. The waste should
NOT be confined.
• Flush surroundings with large amounts of
water.
• Never dispose/allow waste in Common dustbins/drains/sewer lines or other water bodies.

24
Safety – Handling – Release Agent
• Do not empty into drains
• Keep away from heat and ignition sources
• Do not inhale vapors
• Do not induce vomit if swallowed

Storage and Handling of Reinforcements
• Reinforcement Materials are typically Glass
Reinforcement – These have specialized Chemical
Treatment known as Sizing - needs protection
from high humidity or exposure to water
• Follow Instruction and Guidelines as per
Manufacturer’s Material Safety Data Sheet about
Storage, Handling and Disposal Methods

26
Safety – Handling – Reinforcements
• Dust collection system should be in place
Waste disposal equipment needed in work area
• First aid: wash skin with mild soap and water
– Use long sleeve clothing 
– Use Vacuum Equipment to remove fibers
NEVER USE COMPRESSED AIR!

• Pigment Pastes and Colour Pastes
• Store in Original packing and in Cool Dark Place, Away from any
direct source of heat or sunlight – as per guidance of manufacturer
• Cleaning Solvents / Thinners
• These are to be kept in designated area and handled with care to
prevent contamination with Resin, Gelcoat and other Liquid
Additives / Materials.
• Use only OSHA approved Practices when using these chemicals as
they have harmful effects on continuous exposures to these chemicals
• Safety precautions are required and Material Safety Data Sheet must
be followed for Storage guidelines
Storage and Handling of Colour Pastes,
Cleaning Solvents / Thinners

FRP Production – Formula for Success
• Defining Performance Parameters
• Designing the Laminate Sequence
• Selecting Appropriate Production Method
• Selecting Suitable Raw Materials
• Adopt SOP based Production and Quality Validation

Suitable Gelcoat Types for Amusement
Parks and Recreation Industry
• For Mould Manufacturing:
• Modified NPG Isophthalate Based for Open Mold
• Modified Bisphenol A Epoxy Vinyl Ester Based for Match Die Molds
• Modified Novolac Epoxy Vinyl Ester Based for RTM / LRTM Molds
• For Product Manufacturing
• Acrylic Modified NPG Isophthalte Based – UV Stabilized
• Modfied Isophthalate Based – UV Stabilized

Suitable Resin Types for Hand Lay-up /
Spray-up Process
• Modified NPG Isophthalate Based Thixotropic Resin
• Modified Bisphenol A Epoxy Vinyl Ester Based Thixotropic Resin
• Modified Novolac Epoxy Vinyl Ester Based Thixotropic Resin
• NPG Isophthalate Based Thixotropic Resin - *****
• Isophthalate Based Thixotropic Resin - ****
• Orthophthalate Based Thixotropic Resin - ***
TIP: Always Use Thixotropic Version of Resin for Hand Lay-up
and Spray-up to prevent rundown on vertical surfaces

Suitable Resin Types of RTM / LRTM Process
• Modified Bisphenol A Epoxy Vinyl Ester Based Thixotropic Resin
• Modified Novolac Epoxy Vinyl Ester Based Thixotropic Resin
• Vinyl Ester Resin / Isophthalate Resin / Orthophthalate Resin / DCPD
Resin
• Low Viscosity, Low Exotherm, Fast Curing Characteristics
TIP: Always select suitable Curing System, to Enhance Gel To
Cure Behavior to Achieve Faster Demoulding Time

Good Manufacturing Practices for FRP
• Adopting Robust Practices related to Hazards and Safety Standards for
All Departments
• Adopting and Creating Internal Training and Qualification Program for
Manpower to Meet Desired Set Standards for Quality Manufacturing
Benchmark
• Preparing and Adhering to SOP for Every Step of Operation
• Use of Relevant Tools and Accessories for all Operations
• Maintaining Hygiene and Cleanliness in Working Area as well as that
of Tools and Accessories
• In-process Monitoring of Quality Parameters to ensure Quality and
Consistency

Materials, Tools and Accessories for FRP
• Basic Pattern / Mould for Manufacture FRP
• Release Agents and Tools for Its Application
• Reinforcement and Resin (Gelcoat and Lamination
Purpose)
• Curing System (Promoter, Accelerator, Catalyst)
• Preparation Tools – Scissors, Buckets, Measuring
Cylinders, Mechanical Mixing Devices
• Application Tools – Brush / Rollers / Squeezes /
Spreaders

What is the Role of Moulds ?
• Mould Defines the Quality of the Part Produced
• Dimensions and Aesthetics completely depend on the Quality
of Mould
• Investment must be right to achieve the maximum ROI
• Materials Selection and Process Selection Defines the Overall
Cost
• Life of Mould depends on the Materials as well as
Workmanship
• Must Aim for Good Mould to Start With – Good Mould to
Stay With even after multiple cycle of Moulding (say a good
500 numbers!!)

Why FRP Moulds?
Good Quality FRP Moulds Have Following Advantages
• Easy to Produce Complex Shapes and Sizes compared to
Metal
• Light Weight Compared to any other Materials of
Construction
• Long Lasting when Compared to Wooden Moulds
• Repair and Maintenance easy to Patch and Match the Surface
• Relatively Low Amortization Cost compared to Metal Moulds

Most Common Issues in FRP Moulds
• Print-through (Poor selection of Gelcoat)
• Poor dimensional accuracy and loose shape soon after
repeated use for 30 to 100 cycles (This can happen if
Construction sequence is poor or if performance of
Materials used is poor)
• Star cracks on the Mold surface within few cycle of
Molding (Inferior Quality Gelcoat and Layer sequence)
• Frequent polishing required (Low Hardness / Toughness of
the Gelcoat)

Material Options for Patterns and FRP Moulds
• Pattern Materials (POP, Clay, Wood, Foam Blocks,Tooling Board, Tooling
Paste, FRP)
• Pattern Finishing Materials (Hard Coatings based on Polyester /
Polyurethane / Vinyl Ester) + Polishing, Rubbing and Buffing Compounds
• Release Systems – Liquid Wax or Semi Permanent Release System
• Tooling Gelcoat - NPG Isophthalate Based, Vinyl Ester Based, Novolac
Epoxy Vinyl Ester Based
• Tooling Resin – Corresponding resin compatible with Tooling Gelcoat
• Core Materials – Balsa Wood, Structural Foam, Volumnized Mat (Core
Mat / Spherecore Mat), Plywood
• Stiffeners and Frame – Wood, Steel Angles, Channels, Foam Filled
Stiffeners
• Stand / Trolley for mounting the Mould – Steel / Wooden Material

Prepare Good Pattern
• Choose suitable Pattern Material and work to get the desired
shape as per design for Pattern
• Pattern Surface Finishing is done using HDT Coating System,
achieve desired Gloss
• Apply suitable Release System must be applied to Translate
Pattern Finish on the FRP Mould

FRP Mould Design Elements
A Good Mould has three distinct elements
• Functional Tool Surface - About 3 to 5 mm
• Structural Layers – Including Stiffeners
• Support Layers for additional Stiffening / Handling Ease Purpose

Mould Quality & Performance Specs
• Tool Surface Must be:
• Very Tough and High Impact Resistant
• Retain Surface Finish and Resistant to Chemicals
• Robust Resistance to Scratch / Abrasion as a Tool Surface.
• Overall Structural Laminate
• Very Strong and Having High Impact Resistance
• Must be Free from Dimension Variation and Tolerances
• Retain Shape and Rigidity during Use and Abuse

Tool Surface Laminate – (~ 5 – 7 mm thickness)
First Layer of ~ 1.0 to 1.5 mm thickness is made with a specially
formulated Tooling Gelcoat to provide a tough, abrasion resistant and
porosity free surface – Cured to tack free surface
Next two layers are build using Surface Tissue and Tooling Resin –
Cured to tack free surface
Next one layer of 225 gsm / 300 gsm Powder Bonded CSM with
Tooling Resin – Cured to tack free surface
Three to four layers of 450 gsm Powder Bonded CSM with Tooling
Resin – Cured to tack free surface
Constructing FRP Mould
Stage – I : Tool Surface Laminate Construction

1 – 1.5 mm
Gel Coat
1 – 2 layers
Surface Tissue
1 layer
225 /300 gsm Powder Bonded
Chopped Strand Mat
2 – 4 layers
450 gsm Powder Bonded
Chopped Strand Mat
Layering Sequence Start to Finish
Mould Making process- Stage I
Tool Surface Laminate||Construction Sequence

Mould Making process- Stage I
Gelcoat Application
300 gsm CSM Powder
Bonded mat
application
450 gsm CSM Powder
Bonded Mat
application

Mould Making process- Stage II
Applying Structural Core Layer
Structural Cenosphere Core Layer with Cenosphere Core Casting
made with Hollow Microsphere and Polyester Resin Mix
or
Sphere.Core Mat based Structural Core Laminated with Polyester
Resin

Mould Making Process – Stage II
Building Cenosphere Structural Core Layer
Applying Casting putty to
fix Core Layer tiles
Applying Core Layer Tiles

Mould Making Process - Stage III
• Outer Skin Laminate (~ 2 – 8 mm
thickness)
• Laying of 225 / 300 gsm Powder
Bonded CSM on top of Structural
Core layer – allowed to tacky cure
• Laying of further 2 to 5 layers of
Powder Bonded 450 gsm CSM – with
suitable formulation of Tooling Resin
and Cenosphere mix (~ 10 phr) to tack
free cure
• Apply Top Coat as the final coating to
give smooth and integrated tack free
surface

1 layer
225 /300 gsm
Powder Bonded
Chopped Strand Mat
2 – 4 layers
450 gsm Powder Bonded
Chopped Strand Mat
1 layer
Top Coat
Layering Sequence Start to Finish
Mould Making process- Stage III
Outer Skin Laminate

Mould Making Process - Summary
Composite Laminate Mold Sequence – Highlights
Tool Laminate with high abrasion resistance and toughness
Structural Core Layer – integral part of Mold without any
glue / bond line – to provide suitable stiffness and strength
Outer Skin Laminate – Integral part of Mold without any
glue / bond line – to provide suitable protection

Tooling Gel Coat Layer
~ 1.0 to 1.2 mm thickness
Mold Skin Laminate Layer
~ 3.5 to 5 mm thickness
Censophere Core Layer
~ 18 mm – 20 mm thickness
Outer Skin Layer
~ 3.5 to 5 mm thickness
Typical Mold Laminate –
A Cut Out for
Illustration of Elements
of Construction

Spherecore Mat Layer
8 mm
Tooling
Gel Coat Layer
~ 1.0 to 1.2 mm
thickness
Mold Skin Laminate
Layer
~ 3.5 mm
thickness
Typical Mold Laminate –
A Cut Out for
Illustration of Elements
of Construction

Benefits of Sandwich FRP Mould
• Sandwich Laminate Construction can help create desired
stiffness and strength – but without any glue line / bond
line – a monolithic structure – no shear failure
• Mold is made in a short time period with desired
dimensional structure and stability
• Mold surface lasts much longer giving longer life to the
Mold
• Lower Cost Per Piece for Mold
• Better Production Efficiency

Benefits of Sandwich FRP Moulds (Contd.)
• Unique Universal solution to Open Mold / Match Die Mold / RTM FRP Base
Molds / LRTM FRP Base Molds / Ultra Light RTM Molds
• Cost Effective Solution for Any Size / Shape of the Mold
• Live Case Histories:
• RTM Mold: More than 5000 cycles completed on the Mold without any re-
surfacing of the Mold for a part with thicknesses more than 10 mm
• Match Die Molds: Fan Blade Mold for Cooling Towers provided more than double
the production when switched to new concept of Mold making (from 250 to more
than 500 parts before re-surfacing is required / Mold maintenance required)
• Open Mold: Most successful application in the modular panel / modular component
Molds which provided most accurate parts leading to easy assembly of the parts at
site / on the job

Moulds of Different Types for Hand
Lay-up / Spray-up

55
Good Manufacturing Process for Using
Open Mold (Hand Lay-up / Spray-up)

56
Elements of Open Mold Manufacturing
Process
Basic Steps of Production
• Mold Cleaning and Release Applications (HL / Spray)
• Gel coat Application (HL/Spray)
• Application of Surface Tissue (HL)
• Lamination (HL / Spray)
• Demolding (HL / Spray)
• Post Cure and Finishing (HL / Spray)

57
Hand Layup – Basics of Process
Step – 0: Mold Preparation
OR

58
Step – 1 Application of Release System - (Sacrificial Type)
• Wet film thickness of 50-150 microns
• Around 20 – 30 minutes must be allowed for the film to dry, each time before
lamination
• PVA must be stirred well before and during use
• PVA must be washed away from both the mold and the molding after demolding
• Cheapest Direct Cost
• ↑ Thickness  ↑ Ease of Release  ↑ Textured Surface (Brush Marks)
OR

59
Application of Release System
(Non Sacrificial/Semi Permanent)
Apply Release agent
to a clean dry cotton
cloth
Wipe over mold
surface, approx
1 -2 m2
Gently Wipe over
wet coating with a
second dry cloth
Wait 15 sec
REPEAT CYCLE: until entire mold is covered with thin wet film
Repeat steps 3 more
times
Allow to dry (10 min)Allow to cure (30 min)
*Reapply one coat, when the release becomes hesitant
Mold ready for
multiple releases w/o
reapplication*

60
Step – 2: Gelcocat Application
Apply 1st Layer of catalyzed Gel coat on mold
(Brush/Roll)
Allow
Tacky
Cure
Apply 2nd layer of catalyzed Gel coat
Allow
Tacky
Cure
The Final Gel coat
thickness must be
uniform
throughout
Gelcoat must
cover the
entire mold

61
Step - 3: Application of Surface Tissue
Do Not Allow
to Fold
Surface
Tissue
Dab Precut Surface Tissue into Catalyzed Resin
system
Apply a Coat of Catalyzed Resin System
Brush/
Roll
Tacky /
Tack-Free
cure
Surface Tissue Provides
• High quality finish
• Durability in chemical
environment.

62
Step – 4: Lamination
Preferably
Powder Bonded
Roll next layer of Reinforcement in
catalyzed Resin
Roll 1st Layer of CSM in Catalyzed Resin
Tacky/
Tack-free
Cure Roll well for even
distribution of resin
Tacky/
Tack free
Cure
Always maintain equal
distribution of glass to
resin ratio everywhere,
viz., corners, bottom,
vertical surfaces
Consolidation of each
layer before application of
the next layer is essential

63
Step – 4: Lamination (Contd.)
Apply Top Coat with Surface Tissue (Optional)
Further Layers of Resin and
reinforcements are applied, until
desired thickness is reached
Adjust level of
curing additives if
the bottom layer is
still hot
Wait for Peak
exotherm to pass
every 3 - 5 mm
thickness build up
Wait till
partial
cured
Trim the edges with a Sharp Cutting Tool

64
Step – 5 : Demolding
Allow the Molded Part to Cure
inside the Mold
(Few Hours to Few Days)
Demolding:
Use Wedges / Compressed Air
with Pre-designed
Ejector Valves / Pins
Speed up by
heating the
laminate in the
mold

65
Step – 6: Post Curing and Finishing
Put the De-molded parts on a Rigid
Fixture to ensure Dimensional Stability
Post Curing
As per manufacturer’s Recommendations
If required, use
infrared
heaters
Cleaning and Finishing Operations

Latest Trends In FRP Materials and Processes
for Amusement and Recreation Industry
• Design Optimization Tools and Interface with Material Performance
• Advance Resin and Hybrid Reinforcement Systems for
• Zero / Low Shrinkage Tooling Systems
• Flame Retardant Systems
• High Fatigue Life Endurance in All Weather Conditions
• Close Mould Production for RTM / LRTM / ULRTM
• Enhanced Two Side Finish Products
• Better Dimension Tolerances to Achieve Easy and Faster Assemblies
• Use of Mechanised Tools to highly Automated Robotic Operations
• Achieve faster Production with Very High accuracy and Tolerances including material
consumption
• 3D Printing of Composites
• Direct Design to Product Prototype for Validation and Testing
• Tailoring of Product for Every Customer Project

Ultra-Lite RTM (ULRTM) Moulding

Dr. Chaitanya Shah
Director – Mechemco Group
Mobile No.: +91-9821046040
E-mail: csshah@mechemco.com
Website: www.mechemco.com
Manufacturer of Composite Resins

FRP Mould and Moulding for the benefit of Amusement and Water Park, IAC, Manufacturers and Users

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