Raising performance through composites tooling - Highlight

1. Advanced Materials
Raising performance through composites tooling
Quarter 4, 2012

2. Advanced Materials 2
Table of contents
From design to manufacturing Link from design to composites manufacturing
Design model Design model
Master model Master model
RenShape® board materials for master model
RenPaste® seamless modeling paste for master model
SMP vs. Board materials
RenPaste® solution for PEUGEOT
Composite tools Composite tools
Compared advantages
RenLam®, Ren® and RenGel® selection
New development
Araldite® LY 8615 solution for AIRBUS

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Link from design to manufacturing
< Table of content Design model > Master model >From design to manufacturing > Composite tools >

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Link from design to manufacturing
< Table of content Design model > Master model >From design to manufacturing > Composite tools >

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Link from design to manufacturing
< Table of content Design model > Master model >From design to manufacturing > Composite tools >

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Link from design to manufacturing
< Table of content Design model > Master model >From design to manufacturing > Composite tools >

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Link from design to manufacturing
< Table of content Design model > Master model >From design to manufacturing > Composite tools >

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Link from design to manufacturing
< Table of content Design model > Master model >From design to manufacturing > Composite tools >

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Link from design to manufacturing
< Table of content Design model > Master model >From design to manufacturing > Composite tools >

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Link from design to manufacturing
< Table of content Design model > Master model >From design to manufacturing > Composite tools >

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Link from design to manufacturing
< Table of content Design model > Master model >From design to manufacturing > Composite tools >

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Design model
Design / styling model is mostly used by automotive, marine and aerospace industry. Design / styling model is involved
in the very early stage of part manufacturing.
Main features and benefits
!! Not functional
!! For design aesthetic
!! Suitable for market research, mock-ups, and trading fare
!! Full size or scale model
!! CNC machined from CAD
Huntsman offers solutions for manufacturing of design / styling model with its very low density
board materials and seamless modeling pastes.
< Table of content Design model > Master model >From design to manufacturing > Composite tools >

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Master model
Once a composite part has been designed and captured in a digital format, the CAD program can be used to create
a master model, known in the marine and wind industry as plug, by using a CNC milling machine.
Main features and benefits
!! Physical standard for production of mold
!! Composite mould for limited production
!! Full size model
Huntsman offers solutions for manufacturing of master model / master plug with its board
materials and seamless modeling pastes.
< Table of content Design model > Master model >From design to manufacturing > Composite tools >

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RenShape® board materials
Board materials description
!! Polyurethane or Epoxy based
!! Available in standardized size and density
!! Cut and bonded to molding blanks
!! CNC machining from CAD
< Table of content Design model > Master model >From design to manufacturing > Composite tools >

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RenShape® board materials
Main features
!! Very fine surface structure
!! Excellent machinability
!! Good dimensional stability
!! High heat resistance
Benefits
!! Ideal for lay up tools for prepregs
!! Low CTE
!! Bonding with dedicated adhesives XB 5055 A+B
RenShape® BM 5055
CTE 40 10-6K-1
HDT 140°C
Hardness 75 Shore D
Density 0.75 g/cm3
Compressive strength 75 MPa
< Table of content Design model > Master model >From design to manufacturing > Composite tools >

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RenPaste® seamless modeling paste
Seamless modeling paste description
!! Epoxy based
!! 2 components extrudable paste
!! Hand or machine application
!! Applied with a metering / mixing machine on substrate
!! CNC machined from CAD after curing of the paste
!! Once milled, no joints or voids are visible (seamless material)
< Table of content Design model > Master model >From design to manufacturing > Composite tools >

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RenPaste® seamless modeling paste
Main features
!! Very fine and seamless surface
!! Quick model build up
!! Room temperature curing
!! Heat resistance up to 55ºC
Benefits
!! Ideal for design and styling models
!! Low density
RenPaste® SV 4503-1 / Ren® HV 4503-1
< Table of content Design model > Master model >From design to manufacturing > Composite tools >
CTE 100 10-6K-1
HDT 55°C
Hardness 60 Shore D
Density 0.7 g/cm3
Compressive strength 15 MPa

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RenPaste® seamless modeling paste
Main features
!! Rapid cure at room temperature
!! Excellent adhesion to EPS
!! Rapid and easy machining
!! Heat resistance up to 80ºC
Benefits
!! Ideal for master models / plugs and short production-run molds
!! Programmable paste rheology (10 to 40 mm)
!! High slump resistance
RenPaste® 4666 / Ren® 4666
< Table of content Design model > Master model >From design to manufacturing > Composite tools >
CTE 75 10-6K-1
HDT 95°C
Hardness 65 Shore D
Density 0.95 g/cm3
Compressive strength 20 MPa

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Critical properties of master model
RenPaste® products are ideally dedicated for rapid production of large model / tool requiring
seamless finish with easy repair and present additional advantages during processing to
reduce wastage and to be easy machined.
SMP vs. Board materials
< Table of content Design model > Master model >From design to manufacturing > Composite tools >

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Design model of show car Peugeot Flux
Made by D3 design studio with RenPaste® 4666 / Ren® 4666
Benefits
!! Optimal reproduction of contours allowed by the programmable rheology and surface quality
!! Short lead time due to fast cure and machining
RenPaste® solution for PEUGEOT
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Composite tools
Composite mold / tool describes a form with convex respectively concave shape and will be used to fabricate
the final composite part with a concave respectively convex finished surface.
Main features and benefits
!! Production of composite parts
!! Manufactured by wet-lay up, infusion and prepreg
Depending on size, geometry, temperature resistance and durability requirement, Huntsman offers
solutions for manufacturing of composite mold / tool with its product range of laminating systems,
laminating pastes and gelcoats.
< Table of content< Table of content Design model > Master model >From design to manufacturing > Composite tools >

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Compared advantages
Typical and critical properties
Material Density Thermal conductivity Coefficient of
thermal expansion
Temperature
resistance
Cost (2) Durability (3)
SMP (1)
+++ - - - ++ -
GFRP ++ - ++ + ++ -
CFRP +++ - +++ + + -
Aluminum + +++ - + ++ +
Stainless steel - ++ + ++ +++ +++
Invar 36 - + ++ ++ - +++
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(1) Direct to mold
(2) Manufacturing cost not included
(3) Number of manufactured composite parts / production cycle

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Compared advantages
Benefits
!! Low cost tooling method
!! CTE of composite tooling compatible with laminate
!! Low density easier to handle than metal
!! By damage, fast and economical production of new tool
Challenges
!! Withstand severe temperature / pressure
!! Durability
!! Heatable
< Table of content< Table of content Design model > Master model >From design to manufacturing > Composite tools >

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RenLam®, Ren® and RenGel® selection
Standard epoxy systems for composite mold manufacturing
Product designation Application Process Viscosity Pot life Demolding
time
Tack time*
Cure cycle Ultimate Tg Ultimate
flexural
elongation
Conditions 25°C 250 ml, 25°C 25°C
Unit mPa.s min h °C °C %
RenGel® XD 4615 /
Ren® HY 5159
surface coat brush roll thixotropic 25 - 30 1* up to 120 120 - 130 -
RenGel® P99 /
Ren® HY 5159
coupling coat brush roll thixotropic 30 12 up to 100 120 -
RenLam® LY 113 /
Ren® HY 98
laminating
system
wet lay-up
infusion
300 90 - 100 12 (23°C) up to 120 120 - 125 7.0 – 7.6
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RenLam®, Ren® and RenGel® selection
High performance epoxy systems for composite mold manufacturing
< Table of content< Table of content Design model > Master model >From design to manufacturing > Composite tools >
Product designation Application Process Viscosity Pot life Demolding
time
Tack time*
Cure cycle Ultimate Tg Ultimate
flexural
elongation
Conditions 25°C 500 ml, 25°C 40°C
Unit mPa.s h h °C °C %
RenGel® SW 5200 /
Ren® HY 5212
surface coat brush roll thixotropic 10
(250 ml)
24 (25°C)* up to 200 200 -
RenLam® LY 5210 /
Ren® HY 5212
laminating
system
wet lay-up 2 000 12 14 up to 200 230 - 238 -
RenLam® LY 5210 /
Ren® HY 5213
laminating
system
wet lay-up 1 800 2 - 2.5 14 up to 180 170 - 180 -
Araldite® LY 8615 /
Aradur® 8615
laminating
system
infusion 480 - 580 14 -16
(100 ml)
24 up to 180 210 - 220 2.7 - 3.7
Araldite® LY 8615 / XB
5173
laminating
system
infusion 300 - 350 5 - 6
(100 ml)
24 up to 180 210 - 220 4.1 - 5.1

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New development
Application
!! Large-scale mold for composite
!! Suitable for various production process
Main features and benefits
!! Low viscosity
!! Long pot life
!! High heat resistance
!! Low temperature gelation and demolding (40ºC)
!! Free-standing post-cure possible
!! No need of surface coat
Mid Tg infusion RenLam® LY 120 / Ren® HY 99
< Table of content< Table of content Design model > Master model >From design to manufacturing > Composite tools >
Viscosity at 25°C 40 10-6K-1
Pot life at 25°C 230 min
Gel time at 40°C 100 min
Ultimate Tg 155°C
Ultimate elongation 7%

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New development
Compared properties vs. other mid Tg competitive system
Pot life comparison (min)
RenLam® LY 120 / Ren® HY 99 shows an excellent balance between long pot life,
low viscosity and high heat resistance.
< Table of content< Table of content Design model > Master model >From design to manufacturing > Composite tools >

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New development
Compared properties vs. other mid Tg competitive system
Viscosity comparison (mPa.s)
RenLam® LY 120 / Ren® HY 99 shows an excellent balance between long pot life,
low viscosity and high heat resistance.
< Table of content< Table of content Design model > Master model >From design to manufacturing > Composite tools >

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New development
Compared properties vs. other mid Tg competitive system
Tg comparison (°C)
RenLam® LY 120 / Ren® HY 99 shows an excellent balance between long pot life,
low viscosity and high heat resistance.
< Table of content< Table of content Design model > Master model >From design to manufacturing > Composite tools >

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New development
New infusion and new prepreg epoxy system
Application
!! Mold for production of high heat resistant composite parts
!! Serial and prototype production
Evident durability improvement vs. current laminating system
Durability comparison (number of cycles**)
* Combined with RenGel® SW 5200 / Ren® HY 5212 ** Rating based on vacuum permeability, Heat resistance and ILSS after thermal ageing
1 cycle: heating 25-180ºC (3ºC/min) + 2h at 180ºC + cooling 180-25ºC + 1h at 25ºC
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Composite mold for Airbus A350 - Lower panel section 11-12 of the fuselage
Produced by LOIRETECH (France) with Araldite® LY 8615 / Aradur® 8615
Process Infusion
Benefits Easily processable and suitable for large molds production
!! Long work life and infusion at low temperature (23-40°C)
!! Demolding after low temperature precure (35-40°C)
High perfomance
!! Tg > 180°C after post curing
!! Withstand more than 300 production cycles (Airbus 10-4 mbar.l/s mold leak requirement / CETIM)
Araldite® LY 8615 solution for AIRBUS
< Table of content< Table of content Design model > Master model >From design to manufacturing > Composite tools >

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Keep our products at your fingertips
View the brochures on SlideShare
With these brochures get an overview of our
comprehensive range of tooling solutions for
master models and composites production.
Download our mobile apps on your smartphone
With these apps select immediately the right:
!!Araldite® industrial adhesive for your specific need
!!Araldite® composite formulated system for your process / application
Access the product description or send us an email to request
the technical data sheet.
Araldite® - Adhesives (Europe)
Download on iPhone | Android
Huntsman - Composite resins (Europe)
Download on iPhone | Android

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For more information
www.huntsman.com/advanced_materials
advanced_materials@huntsman.com
Europe
Huntsman Advanced Materials (Switzerland) GmbH
Klybeckstrasse 200
P.O. Box - 4002 Basel
Switzerland
Tel. +41 61 299 20 41
Fax +41 61 299 20 40

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publication, nothing contained herein is to be construed as a representation or warranty of any kind, express or implied.