Directions For Use:

1. Add the Part B to the Part A can. (remove rim, if quart or gallon container)

2. Strap can to drill press and mix thoroughly for two minutes (timed) at slow speed (150-250 rpm with a Hapco mixer).

3. Periodically (1 or 2 times), stop the mixer then scrape the sides and bottom of the can during mixing, using a metal spatula.

4. When A and B are thoroughly mixed, slowly add Part C into the container while continuing to mix. Turn Part C slowly, until wet.

5. Immediately cast TOOL-IT  mixture into the wet Tool Cote , while vibrating on the Vibrasonic Table. (note: Always start the vibrator before casting.)

     a) Vibrating creates flow.

     b) Helps remove trapped air up to the back surface.

     c) Orients metallic aggregates for uniform heat conductivity.

Note: For small molds, clamping or taping will prevent movement of the setup during vibrating.

6. Pour material slowly from a height of 8-12 inches, depositing material in all the low points in the mold, until TOOL-IT  is flush to the top frame.

7. After pouring, continue to vibrate for one hour.

8. Cure per prescribed curing schedule.

DEMOLDING:

Prior to demolding, it is best to fly cut the backside flat and parallel.

SURFACE PREPARATION TO PREVENT ADHESION:

To prevent adhesion to the mold, use a GREASE IT release agent. The following are recommended; GREASE IT II, GREASE IT IV, GREASE IT V, GREASE IT FDG, GREASE IT WAX P, or GREASE IT WAX L. For best results, apply in a few thin coats, drying between coats. Porous surfaces, i.e. wood, plaster, etc, must be sealed thoroughly before release is applied. Use multiple coats of a good coating, such as: a high grade lacquer or urethane lacquer.

SURFACE PREPARATION FOR ADHESION:

For applications where adhesion is desired, the surface must be cleaned, abraded and dried. Sandblasting and mechanical roughing are the preferred ways of abrading surfaces to be bonded.
For added adhesion to metals, use Primer 200. Make sure all surfaces are clean, dry and free from moisture.

AIR RELEASE:

Use HAPCO'S ANTI-AIR to aid in air release (see Technical Bulletin). In some products, ANTI-AIR can cause a slight haze to cloudiness. This has no effect on properties.

MIXING:

IMPORTANT: Before each use, mix Part A thoroughly before proportioning out the required amount. Components may separate and should be mixed before each use. Mix, only when ready to use, by adding the curing agent to the resin portion and blending together thoroughly. Be sure to scrape and stir in all material sticking to the sides and bottom of the mixing container. For best results, use plastic or coated containers, and metal or plastic sticks.

CASTING:

Pour in a thin unbroken stream into the lowest point in the cavity or mold. This will help break up some of the air entrapped during mixing. Vibrate during casting for best results.

SHRINKAGE:

Shrinkage or dimensional variation is largely influenced by 5 factors:
1. Mass ( total volume and thickness)
2. The temperature of the material
3. Maximum temperature reached during the exotherm (reaction). The faster the
material, the higher the exotherm, the greater the shrinkage.
4. The temperature of the mold
5. The stability of the mold
Geometry, part thickness, and total volume vary in each design, therefore, the customer is responsible to test and determine the shrinkage factor to be used. The values in the brochures are for comparative reference only, using ASTM testing procedures.

CLEAN UP:

Cured polymers are most difficult to remove. It is best to clean tools and equipment immediately
after use.

RESEALING:

Many polymers are moisture sensitive, reseal, using one of the following two (2) methods: blanket with nitrogen or use a hair dryer for 30 seconds to cover with dry air.

STORAGE:

Polymer systems have a minimum shelf life of six months when unopened. Both components should be stored in a room temperature dry place. When not in use, containers should be kept tightly closed.
(see Resealing)

PRECAUTIONS:

Skin or eye contact with polymers should be avoided. Clean housekeeping procedures are urged and the use of gloves and/or protective creams suggested. All polymers, as a general practice, should be used in well ventilated areas. Spot ventilation is most effective. Contaminated clothing should be removed immediately and the skin washed with soap and water or waterless skin cleaner. Should accidental eye contact occur, wash thoroughly with water and consult a physician.

PACKAGING:

TOOL-IT  is available in convenient and safe pre-measured kits, in the following sizes:

KIT SIZE                  APPROXIMATE VOLUME COVERAGE

Quart Kits                 49 cubic inches/kit

Gallon Kits                196 cubic inches/kit

1 1/2 Gallon Kits      294 cubic inches/kit

5 Gallon Kits            980 cubic inches/kit

These kits are particularly desirable since they eliminate the need for transfer and/or mixing containers. TOOL-IT kits are designed such that the Part A container is large enough to serve as the mixing vessel into which the Part B and C components can be directly added and mixed. The mixture can then be directly cast from the same Part A container.

SUPPORTING FRAME STRUCTURE:

Use an aluminum alloy channel or bar stock of appropriate height to accommodate the height of the model, plus two inches of additional wall thickness, cut to size, and fit to match the mounting frame on the model supporting plate. Drill to match the bolting holes in the base frame.

This frame is required to absorb clamp pressures, and can be used with a matched die tool to provide alignment for the tool.

CAST COMPOSITE TOOLING METHODS:

COILS FOR TEMPERATURE CONTROL - (Curing Assist and Production)

Temperature controls are an integral part of the Cast Composite Tooling System as a curing assist and also for Precise Production Processing (heating or cooling).

As a curing assist - Cast Composite Tooling Polymer Alloys are designed to be temperature controlled during cure. Proper application of temperature coils insures exact reproduction and dimensional stability in Cast Composite Tool production.

This system is a heat activated polymer. Best results are obtained by hardening with the use of a Cast Composite Tooling Thermal Unit, which allows precise control of hardening evenly throughout the mold.

Production - Thermal Control

The other use of the temperature control system is to control heating/cooling in production. Cast Composite Tooling can be run with better control because the coils are mated to the exact geometry of the part to be manufactured. Also, if it is felt that extra cooling or heating is needed in any one area, individual zones can be employed.

Coil Fabrication Techniques

All coils should be positioned in a back and forth method, approximately 1" on center. When two lengths must be joined, compression fittings are adequate. If joints are to soldered, use a solder that will take your operating temperature. Layers of coils must be continued in depth of the mold, as a curing and control assist. Layers may be tacked together, or strung together for positioning, while the backup is being poured. Do not exceed 25 linear ft in one zone. Each bend is equal to 2 1/2 ft in length.

NOTE: The complete coil system should be thought out, fabricated and checked before you begin. This will allow you to build the mold smoothly and successfully.