infusion tooling_step-by-step-guide_single page

Infused Tooling A step-by-step guide.

Table of Contents Introduction 4 Materials and Accessories 6 I. Preparing the Master Mold 10 II. Applying the Gel Coat 12 III. Loading the Glass Reinforcement 14 IV. Bagging the Tool 16 V. Beginning the Infusion Process 18 VI. Applying the Frame 20 VII. Demolding the Tool 22 Additional Resources 24

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Benefits of Infused Tooling Faster process The laminate operation (all layers and cores) can be set up in just one step.

Lighter results Because of the high glass content and better mechanical properties, thinner laminates can be infused compared with other processes.

Stronger tools The infusion process allows for high glass content laminates with excellent mechanical properties.

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Infused Tooling Considerations Plant capabilities The initial infused tooling setup takes time and resources.

Process capabilities Knowledge of tooling systems and parts helps avoid common mistakes and rework.

Tool specifications For purposes of efficiency, it is best to use infusion for tools that are one meter sq. or larger. Anything smaller will result in dimishing returns on prep time and cost.

End application Open mold

Tip: To select the best laminate construction for your infusion mold, AOC suggests infusing a flat panel (12”x24”) using the gel coat, barrier coat and laminate schedule created from previous discussions with our technical team.

With this panel on hand, you can evaluate the performance of the laminate, cosmetics appearance, and mechanicals properties. Also, this panel can help to determine the infusion time (and the resin gel time) for the laminate schedule selected.

Closed mold A side Closed mold B side Glass master

Laminate schedule Gel coat Barrier coat Glass schedule Cores Frames

Scan the QR code to contact an AOC rep about your specific tooling questions.

Materials and Accessories Before beginning the tool building process, it is critical to have a master model that is in good condition to ensure tools will have the surface finish needed to build quality parts.

You will also need the following materials: Glass reinforcement Two different colors of gel coat or a gel coat and a barrier coat Resin formulation Catalyst In addition, you will need the following consumables: Flow media Peel ply Plastic tubing Bagging material Putty Spray adhesive Tack tape for patching holes

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Materials and Accessories

Key Products for AOC’s Infusion System VIBRIN G910 VINYL ESTER GELCOAT

VIBRIN G930 VINYL ESTER BARRIER COAT

A next-generation vinyl ester tooling gelcoat, Vibrin G910 delivers unmatched toughness, gloss, and durability for high-performance molds.

Designed for spray applications behind gelcoat, Vibrin G930 is used to enhance surface quality and structural performance.

High Gloss Finish: Delivers mirror-like surface quality

Minimizes Glass Print: Enhances surface appearance

Dimensional Stability: Maintains shape and integrity under stress Porosity Resistant: Smooth, defect-free surface High HDT: Withstands elevated temperatures

Thermal Shock Resistant: Withstands temperature cycling High Elongation: Improves flexibility and toughness

Tough & Resilient: Excellent impact and abrasion resistance

MOLDTRU LPT-68001 FORMULATION Optimized for room-temperature vacuum molding, MoldTru LPT-68001 enables faster build cycles with no post-cure required.

Faster Build Time: Rapid infusion and cure accelerate mold production Efficient Flow: Low viscosity supports high-glass laminate wet-out No Surface Distortion: Low shrinkage ensures dimensional accuracy High HDT: Ideal for master mold replication and thermal stability No Print-through: Smooth surface finish without glass pattern visibility

The Process of Infused Tooling

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I. Preparing the Master Model Start preparing your master model by applying a complete mold release system to ensure the mold releases from the master cleanly after curing.

Your master model needs to be designed with a minimum 8” flange for tubing and tack tape, and should be strong enough to support the vacuum pressure.

~10 minutes

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A master model with taped flange.

Two workers mix the gel coat and catalyst for the master model in the background.

II. Applying the Gel Coat The next step in the process is to apply the gel coat to the master model. The gel coat is applied in two layers.

Remember to mask 2” around the perimeter before applying the gel coat, for the tack tape location.

Start by preparing the gel coat. Mix it with the catalyst according to the product specifications.

Apply the first layer of gel coat. Inspect for full cure before applying the second gelcoat layer.

Once the first layer is cured, you’ll then apply a second layer of a different color gel coat, or alternatively, a barrier coat if extra protection is needed for the tool. Ensure the second layer is also applied at 20 mils thick.

~2 hours to apply and cure

Optional Step: Applying the Putty Radius After the barrier coat or gel coat is tack-free, apply a light putty on corners and radius to increase the draft angles. This step is only needed when the radius of the tool is smaller than 5mm.

Why are two different gel coat colors recommended?

Using two layers with different colors allows for visually tracking wear on the tool, signaling when rework or polishing may be needed.

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Tip: If you find uncured or wet areas, allow more time OR remove and reapply the layer.

A painter adds the second layer of gel coat.

Scan the QR code to watch a short video demonstrating the gel coat application.

III. Loading the Glass Reinforcement Apply the tack tape around the perimeter of the master model. Then, begin the glass loading process.

Load the glass reinforcement onto the tool.

Carefully position the glass according to your tool design. Use spray adhesive to keep the glass in place and tight to the surface, especially if multiple layers are needed for added strength. If required, core material like balsa or foam can be used to increase mold stiffness without adding excess weight.

Layers of fiberglass are added to the tool.

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~1 hour

Tip: Remember to reinforce the flange and maintain the center flexibility.

Balsa and foam increase mold stiffness.

Scan the QR code to watch a short video showing how the glass reinforcement is added.

IV. Bagging the Tool Put down the peel ply, followed by the flow media, covering the surface of the master model.

The flow media ensures consistent wetting of the glass and an even cure. Then, locate the resin and vacuum feed lines. The format of these consumables will vary depending on the size and shape of the tool and infusion strategy setup.

Next, set up the bagging system. Keep in mind that the bagging material should be three times the amount of material needed for the developed area of the final tool. This should be done by creating pleats, to allow the vacuum to pull the material tight and conform to the master model’s contour.

~30 minutes

Once everything is in place, perform a vacuum drop-down test to check for holes or leaks in the bagging. Use ultrasound equipment, vacuum gage, or manual checks to detect leaks. Ensure the vacuum pressure is consistent, with no more than one inch of mercury per 5 minutes.

Any gaps or holes should be sealed with tack tape to prevent vacuum loss.

Flow media is added over the glass.

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Pleats in the bagging allow for enough material to adequately cover the tool.

Scan the QR code to watch a short video showing peel ply and flow media being added.

V. Beginning the Infusion Process Mix the resin formulation with catalyst according to the product specifications and gel time needed. Once ready, open the infusion tubes to begin the formulation flow. As the infusion starts, monitor closely for any leaks and repair them as needed.

Once the infusion has completely filled the tool, clamp the feed line and keep the vacuum flowing.

Continue the vacuum until the laminate is cured. It is recommended to leave the mold to cure under vacuum overnight. Next, stop the vacuum and remove the consumables, revealing the completed backside of the tool. It should appear completely white, indicating the process was successful.

A clamped feed line.

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~30 minutes for infusion, with overnight cure.

Resin can be seen as it’s vacuumed into the tool.

A fully-infused tool.

Scan the QR code to watch a short video showing the infusion process.

A fully-infused tool after it’s cured, with the bagging removed.

VI. Applying the Frame The next step is to apply a frame to the backside of the tool. To reduce torsion during the demolding process, we recommend applying a steel frame around the tool. Secure the frame at multiple points using adhesive and laminate for stability.

~2 hours to apply and cure

Adhesive is applied to the mold...

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...then laminate is added to the frame.

Tool with finished metal frame.

Scan the QR code to watch a short video demonstrating the frame application.

VII. Demolding the Tool Finally, it’s time to demold the tool. Using wedges, work around the perimeter and pull the tool off the master model. With the tool now demolded and inspected, your composite tool is ready for use or additional processing.

~30 minutes

Wedges are added to the perimeter.

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The final results.

Scan the QR code to watch a short video showing the demolding process.

Infused Tooling Resources

Infusion video

Customer testimonial

Tooling brochure

Tooling product flyer

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