Vacuum laminating

Vacuum laminating

Production of the products in the closed form. First – just as in hand method – we apply gelcoat (manually or by SPRAYING)

Next, we stack structural layers in the mold (glass mats, fabrics, synthetic mats, mats in the form of a sandwich, Coremat, rovicore, etc.) as well as any strengthening and adaptations.

Once that’s done the mold is closed, it can be closed with a specially prepared membrane laminate PWS (punch) or the membrane made of plastic bag or silicone.

In any case, it is critical to ensure tightness of the mold. Once the mold is closed vacuum is being generated and then the mold is filled with a suitable resin through a specially made channels or openings. Resin injection and filtering of the carrier material happens through created underpressure.

Advantages of the method

relatively low start-up cost of production compared to the RTM technology (higher than the manual method production)
profitability of the method with an average-sized orders
the possibility of additional assembly adaptation and / or reinforcements (metal adaptations, PU foam, dividers, etc.)
good venting in the structure of the laminate
low emission of volatile substances to the environment.

In comparison with the manual method:

better quality and uniform structure of products,
a higher density and improved mechanical properties,
higher glass content and the greater strength of the product,
smooth surface on both sides,
greater process efficiency.

Limitations of the method

Apart from technological limitations (eg. Technological radii, wall inclinations), this method can be applied generally for production of elements with less complex shapes. The need to ensure the tightness of the mold and having to take into account designing molds with specific channels for the resin injections would be additional limitations.

Other:

bigger material waste, which is associated with the occurrence of channels for the resin injection,
a wall thickness tolerance up to 0.5 mm,
limited possibility to apply changes to the mold

KRZYSZTOF BRAJA
HEAD OF TECHNICAL DEPARTMENT
tel. +48 65 529 91 91 ext. 104
email: kbraja@astromal.pl

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Examples of technology application

Bus wall

The rear wall of the bus is an example of an element manufactured in vacuum technology. This technology was suggested to the client due to the small complexity of the product. Repeatability, high surface quality of the components and productivity are reflected here.

Hunting pulpit / border control pulpit

Successful combination of design, functionality and durability. Our designers created this project to customer’s order. The portable pulpit was to replace the old wooden ones found in the forests, and also be used by the military.

Light Electric Vehicle

All components of this vehicle were manufactured in our company. The interest in electric vehicles is growing, which is reflected in the interest in composite elements and their installation on the vehicle.