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By starting with the creation of an FRP sculpture mold, we aim to produce FRP products that cater to practical demands in both production and daily life.
First, the glass-reinforced plastic (FRP) sculpture plaster mold:
Gypsum models are heat-resistant, cost-effective, possess low thermal conductivity, and offer excellent replicability. They are commonly used to create master molds. Easy to fabricate, they’re ideal for large-scale items. However, they lack durability, are prone to damage, and dry slowly. They’re best suited for single or intricate linear products like embossed designs. Most of the gypsum used is hemihydrate gypsum, also known as plaster of Paris. Similar to cement molds, a brick base or wooden structure can serve as the foundation, followed by a plaster layer. To enhance rigidity and prevent cracking, fillers such as quartz can be added to reduce shrinkage and fractures. Adding cement (in a ratio of 7:3, gypsum to cement) increases strength. Some suggest incorporating an appropriate amount of latex into the gypsum mix, diluted with water, resulting in strong molds without crumbling.
The plaster mold can act as a master mold for a low melting point alloy mold, allowing the alloy to be cast in its molten form. When creating a sub-mold from a gypsum master mold, a separating agent like potassium soap solution, transformer oil, edible oil, 20% stearic acid mixed with 80% kerosene or gasoline, or even Vaseline should be applied to the master mold’s surface. The plaster mold can be repaired using a water pen and gypsum powder. The drying process involves heating at (60~120)°C for (4~5) hours, naturally cooling, lightly polishing with metallographic sandpaper, and then baking at (100~150)°C for (8~10) hours, followed by heating at (200 to 230)°C for (20~24) hours.
Second, the FRP sculpture rubber mold:
Rubber molds are typically made from silicone rubber or polyurethane resin. They are used to create complex reliefs, round sculptures, and various shapes. These molds are not used alone but require other materials like plaster sleeve molds to function. They are commonly employed in thread-type casting or parts that overlap and cannot be directly removed due to their flexibility. For instance, lion statues, dragon sculptures, or even Buddhist figures and cartoon characters. This method is ideal when the batch size isn’t too large.
Third, the glass-reinforced plastic (FRP) sculpture paraffin mold:
Paraffin molds are utilized for products that are not overly numerous or complex in shape and are difficult to demold. For example, to create a monolithic elbow, including a 90° elbow, two elbows can serve as master molds. After filling the 90° cavity with paraffin, the paraffin core can be slightly removed after removing the master mold. After finishing, an FRP coating is applied to the outer wall, heated and solidified to melt and flow the paraffin, resulting in a complete FRP product. To reduce shrinkage deformation and increase rigidity, around 5% stearic acid can be added to the paraffin. These molds are easy to manufacture, demold, and reusable but lack precision. Another method involves immersing a steel pipe in melted paraffin at 70-80°C, lifting it, and repeating the process until the desired thickness is achieved. The surface can be slightly trimmed before applying FRP. To prevent paraffin from cracking, a small amount of butter can be added to the wax. Alternatively, a thin layer of cellophane can be coated on the outside of the wax as a core. After the glass-reinforced plastic is cured, the heated steel tube melts the paraffin, allowing for demolding.
Fourth, the concrete mold:
Concrete molds are often used for line-type patterns and products with low reusability, such as spiral, wavy, circular, arched, or three-dimensional grooved products. The cost is low, and the rigidity is good. Bricks can serve as a foundation, then covered with cement mortar, polished, filled with putty, and finally polished, painted, and so on. This cement mold can be directly used to produce FRP products or serve as a master mold for reverse FRP molds. The cement mold dries slowly, even under normal conditions, it takes more than a week to perform surface painting such as painting.
Fifth, the FRP sculpture wood mold:
Wood molds are primarily used for large products with flat lines. The wood mold can be directly used as a molding die for FRP products or as a transitional master for reversing FRP molds. The wood used for making the mold includes red pine, ginkgo, fir, etc., and the water content is required to be 15%, which makes it less prone to shrinking and deformation and free of knots. After the wood mold is made, it can be coated with a resin (surface putty) with a thickness of 0.2 to 0.3, and then sanded four times from coarse to fine with water sandpaper. The last time is polished with 800# or 1000# sandpaper, then coated with polishing paste. The polisher is polished and then waxed, making the wood mold ready. It is also possible to directly paint and cover the wood mold to make a wooden mold.
Sixth, the glass-reinforced plastic (FRP) sculpture metal mold:
Metal molds, especially steel molds, are generally used for molded products with small size and large batch sizes. For example, stainless steel plates with smooth surfaces are used when making FRP flat plates; angle steel and channel steel are used for making profiles. Since the molded product is not only pressed but also heated, there are also large products for uncomplicated shapes. Although brass is a common metal, it is easily attacked by resin additives and has an adverse effect on the curing of the resin. It should not be used unless the working surface has been chrome-plated or coated with another metal. The manufacturing and processing of metal molds are difficult and costly. Additionally, the composition of the low-melting alloy mold is: Z 99.3%, A 14%, Cu 3%, M 0.5%, and when the temperature is 50-80 °C, the alloy hardness (HB) is about 100. The utility model has good fluidity but poor wear resistance, and is suitable for manufacturing a plastic molding cavity with a complicated shape and fine patterns, and the use temperature is generally >80 °C. Another low melting point metal is 58% bismuth, 42% tin, with a melting point of 135 °C. The low melting point alloy mold has the advantages of a short molding cycle, simple process, and reusability.
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Hebei Qianmu Fastener Manufacturing Co., Ltd , https://www.qmjgjfasteners.com