Tooling & Foundry
Hapco manufactures several products for making composite tools used in a variety of processes, such as; RIM molding, thermoplastic injection molding, resin transfer molding, and vacuum/pressure forming. Typically, for low-volume applications, composite molds are more economical and faster to build versus aluminum or steel tools.
Composite tooling is produced by building a “frameset” around a pattern. The pattern can be made of almost any material; from machined metal or plastic, to prototypes made via methods like Stereolithography and Fused Deposition Modeling. A “surface coat” is then brushed or poured over the pattern using Hapco’s Surface Coat Systems. These are epoxy-based
formulations that include fillers, such as, aluminum and steel and can withstand service temperatures > 300 degrees Fahrenheit. These materials produce exact surface detail and provide exceptional wear resistance. After the surface coat is applied, a “backup” layer is poured using a Hapcast product or Hapco’s Tool-IT LT or HT. These are high-performance materials that have superior strength and excellent thermal conductivity. When dimensional stability is vital, copper tubing is incorporated throughout the cast backup to allow for thermal control during processing.
In addition to composite tooling materials, Hapco has several elastomeric formulations that are widely used in the foundry industry for making patterns, core boxes, blow tube liners and fixtures. Hapflex 565 (Shore 65 A) and Hapflex 665 (Shore 65-D) are used widely for these applications. Sand casting involves compacting a sand mixture under high pressure around a master “pattern” to form a mold cavity. Molten metal is then poured into the sand mold to cast a part. During the part removal process the mold is generally destroyed, however, the pattern can be reused to make hundreds of molds. Hapflex materials provide the durability and wear resistance needed to withstand the rigors of such an aggressive mold-making process. In an industry study comparing the wear-resistant characteristics of Hapflex to other materials used in this industry, such as; wood, epoxy, aluminum and steel, etc., Hapco’s hybrid urethanes surpassed iron.
Tooling & Foundry Materials
Hapcast™ -Aluminum, steel, and iron filled epoxies used for cast composite and production tooling.
Hapcoat™ – Epoxy-based formulations that can withstand service temperatures > 300 degrees Fahrenheit.
Tool-It™ – Low cost, thermally conductive binder commonly used with aluminum Conductites.
Hapflex™ Series – Hybrid elastomeric materials that are extremely impact and wear resistant.