Get in touch
Ready to talk to Quantum about your next project?
The quality of the finish is determined by the quality of the mould and the application of the gelcoat, where the finest gelcoat finishes can match the gloss and visual quality of a painted finish. Consequently, the mould construction and finish are a focus and priority at Quantum. Special attention is given during the lamination training to the quality and application of the gelcoat. When paired with gelcoats selected from leading suppliers, this enables us to deliver a high quality finish. |
|
|
|
Features can be added into the part during the production stage such as bosses, threaded inserts, brackets, steel or wood reinforcements. Foam can also be moulded in to maintain stiffness while reducing weight and also as a noise or thermal barrier. An additional coat can be added to the inside of a part for hand or spray lay, known as top coat or flow coat. This is applied at the end of the process to provide a solid colour and smoother finish on the inside of the part. Whilst this improves the look, it is not a smooth gloss finish as it conforms to the undulations of the mat and resin. |
Once laminated, the part is allowed to cure, then removed from the mould for trimming and finishing. Typically the part is cured sufficiently to remove from the mould after around three hours, but the product continues to cure over the following days. It’s important that the part is supported sympathetically during this curing stage to minimise any distortion. Quantum make dedicated stands, jigs, trollies and stillages in house, all designed to support the parts safely and securely. |
|
|
|
Hand layThis the most common fibreglass production method; typically used for complex parts or parts with lower volume requirements. Projects which start with small volumes, can be hand laid to begin with and converted to other methods as volumes increase. The first step is applying the gelcoat to the mould which gives the final finish. The gelcoat may be applied by hand or by spray, and typically is black or white, but in many cases is also a coloured finish. |
Once the gelcoat is sufficiently cured, fibreglass mat is wetted out with resin and laid on the mould; this cures into a strong, stiff and lightweight product. The application of a controlled thickness fibreglass mat means that finished part thicknesses can be more tightly controlled than processes such as spray lay. Multiple layers of mat or other core material, such as foam, are applied to build up to the required thickness and strength. |
|
Hand lay process video |
|
Spray layThis can be a lower cost solution as it allows for a faster layup of parts and is typically suited to larger, more open products. It requires specialist equipment, more operator protection and effective extraction, together with a skilled operator to ensure the correct thickness with no build up in corners. In a similar way to all the processes, the gelcoat is applied first to the mould and depending on a number of factors, the gelcoat coat may either be sprayed on or applied by hand.
|
|
|
|
A specifically designed “Choppy gun” is then used to apply the fibreglass, resin and catalyst all at the same time. This is done by a trained operator, following a spraying pattern which deposits an even thickness of the fibreglass onto the mould; depth gauges are used to check the required depth is achieved. The glass is fed from continuous reels, which is chopped into short lengths in the gun head itself – hence the name ‘choppy gun’. Like handlay, multiple layers can be build up to provide the required thickness and strength. Again, a topcoat can be added and the part is left to cure before being extracted from the mould. |
Spray lay process video |
|
|
|
RTM LiteUnlike spray and hand lay parts, RTM Lite is a closed mould process using an upper and lower mould, as opposed to just one mould with the spray/hand lay process. RTM Lite provides a step up in quality, offering better weight and thickness consistency, together with an excellent smooth internal surface finish. Whilst mould costs are higher due to there being two moulds, it is often a preferred choice on lower volume projects due to the advantages in consistency and inner surface finish. For larger volumes it becomes an even more cost effective solution. |
The gelcoat is applied to one or both of the mould surfaces with reinforcements and features fitted as needed onto either the upper or lower mould. The two halves are closed and a vacuum applied to keep the mould sealed. The resin is then introduced into the mould with a specialised injection machine. A separate vacuum draws the resin into all parts of the mould where it is maintained until the part has cured. Once cured, the mould is opened and the part extracted, ready for trimming and finishing. |
|
|
|
In a similar way to the other processes, additional features such as foam panels can be moulded into the part. Moulds can be made that can generate multiple parts during one injection cycle, making the process even more cost effective than injecting a single part. |
The biggest moulding we currently make, believed to be the biggest single shot RTM Lite moulded part in the UK, is a trailer body shell which is big enough to drive a car into! After investing significant time and resource into challenging the norms of what was believed possible, Quantum were happy to showcase our technical ability in actually being able to consistently make parts of this size. |
|
RTM lite process video |
