MOLD PREPARATION PROCEDURES

Transcription

1 MOLD RELEASE PRODUCTS: Mold Release Agents Semi-Permanent Multiple Release Wax-Based Mold Sealants Cleaners Compounds & Polishes Additional Waxes Supplementary Products MOLD PREPARATION PROCEDURES

2 To Our Valued Customers: Over the years, Finish Kare (FK) has promised and delivered new products and new procedures for the mold release industry due to our heavy emphasis on R&D. Thus, we have been able to continually improve upon old products and create new products to keep up with the changing Industry. This new brochure is presented to you to introduce new product concepts as well as provide simplified and improved mold preparation procedures. Both will help reduce your time, labor and materials and ultimately your production costs. The brochure is divided into 2 sections; Section 1 highlights the key features of FK s products and their uses while Section 2 focuses on mold release procedures. We would like to take this opportunity to thank you, our customers, for supporting Finish Kare over the years with your continuing business as well as your feedback on our products to make them better. Please feel free to give us your comments and let us know if you have any questions about our products or their uses. TABLE OF CONTENTS SECTION 1: FINISH KARE s Mold Release PRODUCTs Wax-Based Mold Release Agents Non-Wax-Based Semi-Permanent Mold Release Agents.. 4 Cleaners Mold Sealant Compounds and Polishes Additional Waxes Supplementary Products SECTION 2: MOLD PREPARATION PROCEDURES Using #1000P: Hi-low Paste Wax Using #135T: Semi-Permanent Polymer Release Agent.. 11 Glass & Stainless Steel Molds Urethane & Elastomer Resins Molds Resin Transfer Molds (RTM) used with Densified Marble & Densified Granite Buffing & Polishing of Mold Storing Molds Rejuvenation of Older Molds Anti-Stat Release System Preventative Mold Maintenance Product Comparison Chart Sincerely, Jitu JJ Jhaveri, President FINISH KARE PRODUCTS, Inc.

3 SECTION 1: Mold Release PRODUCTS This section provides information for the products used in the three key steps in the preparation of molds: MOLD RELEASE AGENTS MOLD SEALANTS CLEANERS, COMPOUNDS and POLISHES WAX-BASED MOLD RELEASE AGENTS: #1000 Series Mold Release Waxes are formulated with the help of today s modern chemistry. Thus, they work in extreme conditions of accelerated-exothermic, high-temperature conditions (HIGH) and low-toambient-temperature conditions (LOW). HI-TEMP and HI-LOW 1000 Waxes contain a blend of synthetic waxes that reduce the quality fluctuations that are found in natural organic waxes such as carnauba. Synthetic waxes that FK uses in its mold release waxes have the high melting points and the proper hardness to get the desired film properties on the mold surfaces. The resulting film has a high gloss and intensive wear-resistance under the high or low temperature molding conditions. This assures an easy release. PLEASE NOTE: EACH OF THE 1000 SERIES WAXES CONTAIN DIFFERENT BLENDS OF SYNTHETIC WAXES AND SOLVENT MIXTURES TO GET THE DESIRED AND UNIQUE PROPERTIES. #1000P: HI-LOW PASTE WAX Contains a blend of synthetic waxes and is one of FK s premium mold release waxes. Proper application of this wax will result in a film that has high gloss and has resistance to intensive wear, heat and water. Good for up to 275º F or 135º C. #888: Max Mold Release Paste Wax Similar in hardness to #1000P. It is yellow in color and has a peculiar, turpentine smell. Comparable to Meguiar s #8. Our extensive testing shows that you get equivalent or better release with #888 than the comparable Meguiar s product. Good for up to 230º F or 120º C. This is one of our newer products sample requests welcome. #333MR: BLUE WAX True high-gloss paste wax. Withstands high-temperature exothermic reactions of resins and does multiple releases easily. Contains carnauba wax, synthetic waxes and high-temperature resistant resins for effective multiple releases of plastic parts through numerous cycles. Good for up to 230º F or 110º C. Buttery texture provides easy on/off applications. Sets up faster and harder and assures quick, clean releases without wax buildup or transfer. Recommended for the effective release of any FRP or cultured marble parts, polyesters, polyurethane, etc... #1000L: HI-LOW LIQUID WAX Specially designed for use between multiple releases to relieve the wax build up and reduce surface tension in molds. Helps to prolong the life of multiple cycle releases. Solvents in the product liquefy the mold release waxes to form an even coat on the mold for easy de-molding. #1165: HI-TEMP EXTRA HARD PREMIUM WAX As the name implies, designed to withstand higher temperatures and is harder than other waxes. Good for up to 275º F or 135º C. USAGE: Higher temperature exothermic reactions. #1006: PRE-RELEASE DETERRENT PASTE WAX Specially designed to reduce the slip factor, which under some situations might allude to pre-release. In the event pre-release occurs on corners, wells and radiuses due to excessive exothermic heat generated by mass chopping over these areas due to repeated passes, apply #1006 as the last coat or last two coats over the application of #1000P prior to gel coat and lay up.

4 Mold Release PRODUCTS WAX-BASED MOLD RELEASE AGENTS: # : GEL COAT RELEASE PASTE WAX Formulated so as to be brushed over gel coat before the final wax coat is applied without worrying about fish eye. Recommended to be applied to any mold surface, whole or partial, where brushing the gel coat on the mold is required. Can be used over #1000P as the final coat or used by itself when gel coating. APPLICATION TIP: A camel hair soft brush is recommended for brushing gel coat. Cutting the tip of the brush helps to get even distribution lay your brush flat while applying. Do not use the tip of the brush because it may remove the release film and causing spot bonding. Apply thin coats; making sure it is dry before wiping. #1000L-28: SPRAYABLE HD MOLD RELEASE WAX Heavy-duty (HD) cousin of FK s #332: Hand or Spray Interphase Release Wax. Contains the same high-melt synthetic blend waxes incorporated into #1000P: Hi-Low Paste Wax and #1000L: Hi-Low Liquid Wax but the solvent systems have been changed to reduce viscosity and make the product sprayable. Field tested and fully embraced by all users because it gets the job done especially for larger molds, panels and other large jobs that require excessive labor for application of paste or liquid waxes. Very easy application just spray on, allow it to dry and then wipe lightly quick and easy. Cuts your labor costs and increases your productivity. NON-WAX-BASED SEMI-PERMANENT RELEASE AGENTS: #135T: POLYMER RELEASE AGENT A polymer-based release agent which has high heat stability. It s polymers provide multiple releases and protection from high heat generated from accelerated exothermic reactions. It is specially designed for: Accelerated Exothermic Resins up to 400º F or 204º C Multiple Releases Compression Molding Vacuum Bagging Resin Transfer Molding (RTM) NOTE: For best results, use terry cloth or Turkish towels when applying #135T. Apply in a circular motion to mold by overlapping previous area. Work product in thoroughly over the mold creating a thin even coat. Check for uniform coverage. Allow it to dry. Reapply as directed. #135T may be sprayed. When applying, if sprayed, we suggest wiping it lightly over sprayed film for uniform coverage. #135ER: URATHANE RELEASE AGENT It is recommended for the following types of urethane moldings: 1. Elastomer Urethane 2. Polyisocynate Component A 3. Hydro-Resin Component B 4. Urethane Foam 5. Isocynate Component A (Diphenylmethone) 6. Poly Component B (Polypreponal Glycol) Note: For #135 ER, follow the same guidelines as #135T.

5 Mold Release PRODUCTS CLEANERS: These are solvent cleaners to clean and remove any foreign matter from the mold surface to get it ready to seal them before applying release agents. #69: MOLD CLEANER & STRIPPER Specially formulated for the Fiberglass Reinforced Plastic (FRP) Industry to clean molds and relieve the problems of wax build-up & over-spray from mold surfaces. Important mold release components of Hi-Low Temp 1000 series waxes are specially blended in this product to liquefy and remove most waxes from the molds. Can also be used as an inter-phase item for the wax system for prolonged releases and as a cleaner for sharper molds and parts. Please note #69 does not relieve Styrene burns. #80: LIQUID MOLD CLEANER Same usage as #135-80, but #80 is milder and contains no toluene or polymers. Specially formulated for cleaning Elastomer Resins (ER). Contains special surfactants that do not react with the resin that other cleaners might. # 69AS: ANTI-STAT MOLD CLEANER & STRIPPER Same as above, but contains anti-static agent which helps to reduce dust and particle attraction to molds due to buildup of static charge. #135-80: POLYMER MOLD CLEANER AND WAX REMOVER Solvent-based mold cleaner for removing wax. Contains toluene and fortified with polymers. A much stronger cleaner than #69 that can be used for the clean-up of all types of molds prior to applying porosity sealing agents and mold release agents wax-based or otherwise. Apply at least 2 coats of # for proper cleaning of molds and assured releases. MOLD SEALANT: Molds are porous so they need to be properly sealed to prevent two things: 1. Release waxes and agents getting into pores and compromising easy multiple releases. 2. Resin getting lodged in the mold and allowing a part to get stuck. APPLICATION PROCEDURE for FK s CLEANERS: 1. Apply #69, # or #80 over a controlled area by saturating a terry cotton cloth with the product. 2. Agitate and wipe wet. Wiping wet allows to pickup foreign matter which have been dissolved or dislodged by agitation. 3. Continue this procedure until the entire mold has been cleaned. 4. Reapply a light, even coat of #69, # or #80 to assure a non-waxy, greaseless surface and wipe. 5. If there is heavy build-up of wax, repeat the process. #86: SEAL KOTE A polymer solution designed for efficient sealing of porosity in new and rejuvenated molds. Aids and assists the wax release agents to assure a clean and easy demolding.

6 Mold Release PRODUCTS COMPOUNDS and POLISHES: Mold surfaces get damaged and warped due to wear and tear of constant use and heat generated during exothermic reactions from the resins. The compounds and polishes listed below are used to repair the molds periodically to make them work like new. They extend the life of molds by getting more use out of them and, as an added bonus, better quality parts are produced. #103: EXTRA HD CLEANER FK s premium cleaner that incorporates glazing and spreading agents. Cleans deeper without any heavy abrasive action. Easily relieves buffer swirls, paint and gel burns; Smoothens and removes fine scratches and blemishes. Assures a deeper and cleaner finish on molds for sharp looking parts. Recommended for rubbing out slight imperfections in the mold or finished parts and for removal of oxidation and/or discoloration of older parts. #600: WHITE FINE RUBBING COMPOUND (PASTE) Fast cutting compound that can be applied by hand or machine. Recommended for rubbing out fine mold imperfections and fine or minor scratches. Removes and blends or does touch up of mold surfaces when removal of foreign matter is essential. Can also be used in heavy-duty work. #923: MICRO POLISHING COMPOUND A fine micro compound formulated to remove sandpaper marks and imperfections quickly and easily while leaving a high gloss and minimizing swirl problems. Easily removes 1500 grit sand marks with a 100% wool cutting pad and 2000 or finer grit with an aggressive foam pad. Can be applied to all painted or gel coat surfaces. #330: MINI BUFF Made with a heavy wax base. Fine polishing compound used for the final machine polishing and dressing of molds before sealing and waxing. Improves clarity and luster. Excellent for older parts where light buffing may be required. #440-5: POLISHING COMPOUND Specially formulated for removal of wet or dry sanding marks, imperfections and other mild defects without scouring the gel coat. A fast cutting compound formulated with fine abrasives and silicates to remove fine to medium scratches and blemishes. Can be used on all gel coated surfaces as well as other mold materials. Please note the products are listed in order of their aggressiveness, such as #103 is more aggressive than #440-5.

7 Mold Release PRODUCTS ADDITIONAL WAXES: #68: EDGE WAX Formulated specifically for FRP and cultured marble industries where a flange- or edge-wax is required to assist in the prompt and easy release of the part. Edge Wax is a semi-paste and it incorporates synthetic waxes into a system that forms a film that is virtually unbendable when applied as follows: 1. Apply 3 consecutive coats of #68 Edge Wax. Allow each coat to dry before applying the next one. 2. Apply 2nd and 3rd coats to all flanges, corners, edges and areas where a gloss is not required. This builds up a wax surface that will produce multiple releases and should only require periodic application unless the area is marred when pulling the part. 3. Reapply the Edge Wax to affected areas and a thin coat all over to get an even film. #332: HAND OR SPRAY INTERPHASE RELEASE WAX Synthetic, polymer resin based, low viscosity sealant that can be sprayed or wiped on the prepared mold. Highly recommended as a spray base mold release wax for all non-skid areas. #604B: MOLD SEALER & RELEASE AGENT Apply in the following manner: For High Shine: Spray on, allow it to dry and wipe off. For Dull Finish: Spray on, allow it to dry, wipe off surplus from only outside surfaces. On non-skid area, just apply but do not wipe. PLEASE NOTE: THIS PRODUCT SHOULD ONLY BE USED IN THIS MANNER AFTER AT LEAST ONE PART IS DEMOLDED WITH FK s PASTE WAX. Formulated exclusively for the FRP, cultured marble and onyx manufacturers. Semi-viscous paste wax that may be brushed or wiped on. White in color so that it will not discolor. Also effective in release hats, flanges and back splashes. Use as follows: Apply three consecutive coats of #604B with a brush, cloth or sponge, one coat at a time. Allow each coat to dry before applying second and third coats to all flanges, hats and back splashes where gloss is not required. This builds up a wax surface that will produce multiple releases and should require only periodic application unless area is marred when demolding. In this case, reapply # 604B to the affected area(s). # PB-1: TRAFFIC WAX Blend of synthetic waxes designed to seal porous surfaces where resins and gels might accumulate. Can be mopped or wiped on. Reduces clean-up time and increases efficiency in production. Eliminates fire hazard by removing the use of paper. One gallon of #PB-1 will cover approximately square feet on porous surface and up to 400 square feet on smooth non-porous surface. Recommend using three applications; Allow each coat to dry prior to applying the next coat assuring proper coverage. #626: POLYMER HAT WAX Formulated for cultured marble, granite and onyx manufacturers. Blend of synthetic waxes, polymers and resins for high-heat stability and multiple releases. Brush or wipe on three consecutive coats of #626, one coat at a time allowing each coat to dry before reapplying second and third coat to all hats, flanges, corners, edges and areas where a gloss is not required. Do not wipe. This builds a wax surface that will produce multiple releases and should require only periodic application unless area is marred when pulling a part. In this case, reapply #626 Polymer Hat Wax to affected area. NOTE: On some molds Polymer Hat Wax acts as a transfer wax, whereby it will be removed with the first, second or third pull and will leave a bright shine on the mold. This shows that the polymer resin has fused to the mold and it will allow several additional releases without reapplication. As the mold dulls down or the part pulls hard, reapply and continue cycle. IMPORTANT: When changing products, or periodically as a mold maintenance program, you need to clean the molds. This reduces resin transfer, wax build-up, hazing, etc... FK has developed a special polymer mold cleaner, # for this purpose. It will deter build-up of wax and styrene resin and will assure longer mold use with continuous releases. #135-80, Polymer Mold Cleaner inclusively forms a film on the mold that deters build-up, and extends the use of #626 by giving additional releases, thus reducing costs.

8 Mold Release PRODUCTS ADDITIONAL WAXES (cont.): #331-21: STORAGE WAX Incorporates a blend of polyethylene resins, polymers and sun screening agents to form a protective barrier against exposure, inclement weather, heat, and ultraviolet solar rays. A protective coating without the extreme and difficult problems of removal that most products of this nature represent. Recommend use of either pressurized or siphon spray gun as an applicator. When spraying, do not to exceed gun pressure greater than 40 PSI. Adjust fan to desired width over a pre-cleaned surface. Spray one coat; allow it to dry. Cross spray, allow to dry. Spray flow coat to desired thickness for proper coverage. REMOVAL: On molds that have been exposed to weather conditions and have become coated with dirt, dust or grit, hose off entire mold to remove debris prior to washing and wiping. Wipe with cloth or wash with simple soap solution under agitation. In extreme cases, wipe down with with FK s #69: Mold Cleaner & Stripper to remove the wax. Re-wax the mold by reapplying one or two coats of wax release agents and then place it back into production. SUPPLEMENTARY PRODUCTS: PVA BY FK Three products available: #64 PVA Clear / #65 PVA Blue: for fine film work #664 PVA Satin Finish: for onyx resin surfaces, for marble industries w/ or w/o gel coats. #67 PVA Green: for heavy duty work. Blend of resins and plasticizers that give a spray film its elasticity and complete coverage unequaled in the industry. Consecutive coats create desired soft tone or dullness. PVA APPLICATION: 1. Set spray pressure not to exceed 25 PSI. 2. Spray a fog coat and allow film to dry to firm tack. 3. Cross-spray to get the complete coverage and allow film to dry to firm tack. 4. Spray a flow coat of 4 mil thickness. Note: Make sure final coat is completely dry prior to spraying gel coat or casting. #PV-6: SPRAY OR BRUSH RELEASE AGENT #PV-6 is a tool maker s friend. This film forming agent serves as a sealer and release agent in liquid form. The resulting release film dries immediately and polymerizes quickly. #PV-6 in lieu of PVA may be applied when the relative humidity is high and the ambient temperature is low. Unlike PVA which will separate and fish-eye or dissolve when sprayed over moisture, #PV-6 will bond to and develop a release film in spite of the moisture contents of any substrate or surface. Thus, #PV-6 can be sprayed over plaster, clay, wood varnish and shellac surfaces that may contain moisture of various types. NOTE: Those of you who are in tooling or who are making your own molds or own prototypes with plaster, clay etc. should consider #PV-6 that gives immediate results without the problems. It contains no waxes or silicone. This product is directed to tooling masters and for breaking in new molds. APPLICATION: As in PVA, spraying is preferred, although brush application can be used. When spraying, use PSI. Apply a first coat, known as Fog Coat. Allow it to cure minutes. Then apply a 2nd coat, a Fill Coat (a bit heavier). Finally apply a 3rd coat, Flow Coat, assuring adequate coverage and an even and a continuous film (3 to 4 mils thickness is required). Allow the last coat to cure thoroughly before laminating or casting. Once solvent odor has disappeared, mold is ready for laminating or casting. If brushing is preferred, use a soft bristle brush. Brush as you would do in varnish, shellac or lacquer. Use a well-filled brush with light, fast strokes and work from wet to dry areas. A fairly heavy first coat is suggested for proper coating followed by lighter applications to fill in pinholes or build up thin spots. TO REMOVE COATING: If the film is of proper thickness, it can be blown off with air nozzle. If not, remove it with acetone. Also clean spray gun with acetone. #641C: SURFACING AGENT A non-styrene intermix surfacing agent is available at greatly reduced costs. Can be sprayed or brushed on. Greatly reduces pin holes, resin tack and air bubbles. Leaves a non-porous surface. Add 1-2% by weight to resin.

9 SECTION 2: MOLD PREPARATION PROCEDURES General procedure for preparation of molds for making parts can be described in three easy procedural steps: 1. Cleaning the mold surface 2. Sealing porosity of the mold surface 3. Application of mold release agents In the case of old molds, one has to rejuvenate the mold surface or make the mold surface like new by sanding and applying compounds & polishes depending on the conditions of the mold prior to following the above outlined procedure. Various types of mold materials are used depending on what types of products are being cast. In general molds are made from: Aluminum Stainless Steel Tempered Glass Densified Marble Densified Granite Urethane, which includes, Elastomer Urethane, Polyisocynate Component A, Hydro Resin Component B, Urethane Foam, Isocynate Component A (Diphenylmethone), Polyol Component B, etc Epoxy Plaster, etc FRP Gel Coat Some of these mold materials require special attention and preparation. Thus, on the following pages, we provide the necessary information about how to handle various types of molds as well as specific procedures and the materials required to work with each of the mold materials listed above. Please feel free to copy any of the following procedural pages for shop personnel. Hang in the work area for easy reference and better demolding.

10 MOLD PREPARATION USING #1000P: HI-LOW PASTE WAX Finish Kare (FK) recommends the following procedures for new molds. The same procedure is also used in its entirety when old molds are sanded, compounded and polished to remove scratches and blemishes after molds are damaged due to their use. CLEANING: STEP 1: Clean the new mold by applying one (1) coat of #135-80*: Polymer Mold Cleaner and Wax Remover. Agitate and wipe while wet. This will help remove the contaminants and debris that have been dissolved, dislodged and have become loose from the mold. STEP 2: Then clean the mold by applying one more coat of # as done in Step 1. Let it dry thoroughly and wipe. In some cases a 3rd application may be required. Just make sure it looks and feels clean by running your finger over the edges of the mold. (Please note: Never touch the inside of the mold surface with your fingers because it will leave oils from your finger tips on the mold surface and may hinder sealant bonding.) SEALING POROSITY: STEP 3: Now apply a coat of #86: Seal Kote. Allow it to dry thoroughly for about minutes, and lightly wipe. (Please note: Drying time may depend on weather conditions.) STEP 4: Reapply another coat of #86 and allow it to dry, wipe lightly and let it set for an about 60 minutes. This will allow the polymer to set and bond to the mold surface and will leave a nice intact, uniform film. Wipe the mold dry with a soft, clean cloth. It is best to use terry cloth or cotton towels. APPLYING MOLD RELEASE AGENT: STEP 5: Apply #1000P: Hi-Low Paste Wax in five (5) separate applications. Make sure that each coat is dry prior to wiping. Please crisscross each application to assure complete coverage. Apply wax in a circular motion to work the wax in. STEP 6: Allow 30 minutes to set after the final wipe then re-wipe. Pour the first part and release it. STEP 7: After releasing the part, gently wipe the mold, then apply one more coat of wax and release one more part. At this point, Mold is cured to the point that Multiple Releases Are Possible. STEP 8: When a part gets a little hard to pull, apply one coat of #1000L: Hi-Low Liquid Wax, let it dry and wipe lightly. Run more parts and apply #1000L as needed. Use of #1000L helps in preventing wax buildup and thus helps in multiple releases. NOTE: While tooling Gel Coat or Green molds, use at least 4 applications of #86 per the instructions to the left. Please allow ample time for each coat to dry prior to wiping it and reapplying. PRECAUTIONS: 1. Make sure each coat of wax is dry prior to wiping it. 2. Allow a minimum of 30 minutes to dry each coat of wax. In extreme cold temperatures and high humidity or inclement weather, please allow additional time (45-60 minutes) prior to wiping. Before wiping make sure wax coating is dry. 3. For best results, use Turkish-type cotton towel to wipe off. 4. In the event mold has become scarred or shows any visible blemishes or scratches, re-work this area (or preferably the entire mold) before pouring any new part. NOTE: Some mold manufactures recommend the spraying of one coat of PVA over wax for several releases when breaking in a new mold. We recommend use of FK s #PV 6: Spray or Brush Release Agent mainly for tooling application. #PV 6 is a solvent based film former, it dries quickly and may be used over plaster, etc... where moisture may be present. Once the mold is cured, this procedure may be eliminated and multiple releases wax system may be put into practice. * # is one of our newer cleaners. In the past we used to recommend use of #69, which is still available. # is little expensive compared to #69; however, it is a much better cleaner and will accomplish your cleaning much more quickly and efficiently; thus resulting in overall cost savings. # contains toluene as one of the cleaning component so it may not be suitable in certain cleaning conditions. Under these circumstances #80 will do a good job for you. FINISH KARE PRODUCTS, INC. T: F:

11 MOLD PREPARATION USING #135T: SEMI-PERMANENT POLYMER RELEASE AGENT This procedure may be used on New Molds, Reconditioned molds, tooling plugs or Release System Change Over. Some of these molds may have been sanded, compounded or polished. CLEANING: STEP 1: Pre-clean the mold with #135-80: Polymer Mold Cleaner & Wax Remover. Soak cloth with the product, apply it to surface, agitate and wipe while wet. Clean small areas at a time and continue in this manner and treat the entire mold. STEP 2: Apply a 2nd thin and even coat of # Allow to dry and wipe gently. If there is a heavy wax build up, repeat the cleaning with # until you are fully-satisfied and the mold is clean. SEALING POROSITY: STEP 3: For sealing porosity and to assure a better release, apply 4 coats of #86: Seal Kote. Please allow each coat to dry thoroughly before applying the next coat. Wipe lightly between each coat so that you are leveling the material and not removing it. APPLYING THE MOLD RELEASE AGENT: STEP 4: Apply 4 consecutive coats of #135T: Polymer Release Agent and allow each coat to dry a minimum of 10 minutes. DO NOT WIPE. #135T may be sprayed. If sprayed, wipe it lightly over the sprayed film to get uniform coverage. For Best Results: Use Turkish cotton or terry cloth towels when applying #135T. Apply it in a circular motion overlapping previous areas. Work product thoroughly over the mold creating a thin even coat. Check for uniform coverage. STEP 5: Apply an extra coat of #135T on all radiuses, corners and wells. Allow it to dry for 15 minutes and then wipe lightly to get an even coat. STEP 6: Laminate or cast your first part. STEP 7: Release the part. After this first release, reapply one more coat of #135T. Continue with multiple releases and reapply #135T, as needed when the pull becomes a little hard. NOTE: We cannot stress enough the importance of the mold being clean prior to applying the release coat. In addition, make sure each coat, including the final coat, is dry and cured prior to casting or wiping. We recommend that each coat of wax or #135T be thin so it will dry better. FINISH KARE PRODUCTS, INC. T: F:

12 PROCEDURE FOR GLASS & STAINLESS STEEL MOLDS ALL GLASS MOLDS SHOULD BE MADE UP OF TEMPERED MATERIAL. CLEANING: STEP 1: Wash mold with soap & water. Then, apply one coat of #135-80: Polymer Mold Cleaner and Wax Remover. Spread, agitate and wipe wet. Make sure that mold is clean. Wiping wet allows one to pick-up loose debris and contaminants. STEP 2: Apply one more coat of #135-80, agitate and wipe wet. Reapply # and allow it to dry thoroughly, wipe off film. At this point the surface should be friction free, bright and shiny. SEALING POROSITY: STEP 3: Apply 4 consecutive coats of #68: Edge Wax. Spread the wax evenly over the surface of the mold. Allow each coat to haze before buffing it into the mold using a 100% wool cutting pad until the wax disappears and creates a high gloss surface. APPLYING MOLD RELEASE AGENT: STEP 4: Apply 5 consecutive coats of #1000P: Hi-Low Paste Wax. Allow each coat to dry thoroughly before wiping it gently. STEP 5: Pour part, inspect mold and apply one more coat of #1000P and proceed with multiple releases.. CLEANING: PROCEDURE FOR URETHANE & ELASTOMER RESINS MOLDS STEP 1: Wash the mold with #80: Liquid Mold Cleaner, agitate and wipe wet. Apply a 2nd coat, let it dry. DO NOT WIPE. APPLYING MOLD RELEASE AGENT: STEP 2: Apply 2 consecutive coats of #135ER : Urethane Release Agent and allow each to dry for about 20 minutes. DO NOT WIPE. STEP 3: Now apply 4 consecutive coats of #135ER and let them dry for about 20 minutes between each coat. Do not wipe other coats, but wipe only the last coat. STEP 4: Allow the last coat to cure for about 45 minutes before pouring matrix. Release the part and apply one more coat of #135ER. Now the mold is ready for multiple releases. STEP 5: Reapply #135ER as needed when the part becomes a little hard to pull. FINISH KARE PRODUCTS, INC. T: F:

13 PROCEDURE FOR RESIN TRANSFER MOLDS (RTM) USED WITH DENSIFIED MARBLE & DENSIFIED GRANITE The following procedures and products are recommended to assure you of proper mold preparation to get clean multiple releases when making densified products using the RTM system. 1. Cleaner #135-80: Polymer Mold Cleaner and Wax Remover 2. Porosity Sealant #86: Seal Kote 3. Mold Release Agent #135T: Polymer Release Agent. NOTE: THIS PROCESS USED ONLY ONCE ON THE NEW MOLD WILL BE SUFFICIENT TO BREAK IT IN. ON REPAIRED SURFACES PLEASE FOLLOW THE PROCEDURE LISTED BELOW: CLEANING: STEP 1: Saturate the cotton cloth with FK S # and apply it quite wet and agitate thoroughly. Work a small convenient area at a time, wipe while wet. Continue to clean the entire mold in this manner. STEP 2: Reapply # in a light even film while working the product well over all surfaces until a light, waxy film appears. Allow it to dry, wipe with a clean cloth. # acts as a cleaning and stripping agent. SEALING POROSITY: STEP 3: Apply #86 over the entire mold by working down to a light, even and transparent film. Allow it to dry and set for 30 minutes. DO NOT WIPE. STEP 4: Apply a 2nd coat of #86 in the same manner; once again allow it to dry. Do not wipe. STEP 5: Now apply a 3rd coat of #86 in the same manner, but, after letting it dry, wipe lightly to get an even film. APPLYING MOLD RELEASE AGENT: STEP 6: Apply #135T in a light, even film over #86. Allow it to dry for 30 minutes and wipe lightly to get a nice gloss. STEP 7: Apply one more coat of #135T to assure that all the areas, such as radiuses, corners, and wells are completely covered. The little extra here and there will provide extra insurance for easy de-molding. Let this last coat of #135T dry for at least one hour, wipe it lightly with a clean soft cotton cloth to a nice glossy finish. Let it set for additional 15 minutes and place the mold into production. This will effectively start the multiple release cycle. When parts show surface tension upon demolding and the release is getting harder, reapply a coat of #135T in the same manner. CAUTION: 1. This entire procedure needs only to be repeated from step 1 if damaged or affected area(s) are repaired by sanding, compounding & polishing. The repair process will strip the mold of all waxes, sealant and mold release agents. 2. Periodically the sealant and the mold release agent film will degrade through the sealer base depending on the amount of granite used and vibrations in the mold. This will show up when you see spot sticking and some areas are getting harder to release. When you observe this, repeat the entire mold prep procedure from the beginning to assure proper mold preparation and easy demolding. 3. An extra coat of #86 on areas showing abrasion will assure additional demolding cycles. FINISH KARE PRODUCTS, INC. T: F:

14 PROCEDURES FOR BUFFING & POLISHING OF MOLD STEP 1: After sanding, buff the entire mold with FK s #923: Micro Polishing Compound or #440-5: Polishing Compound. Use of a wool cutting pad is recommended. FK s #440-5 is more aggressive than #923. If the mold is not really bad, FK s #923 may be used for finer scratches and blemishes and #440-5 may be used for deeper scratches without sanding. (Selection of either heavy duty compound, mild compound and or polishing compound will depend on what kind of shape the mold is and how much work it requires. Additionally, the selection of product will depend on hardness of the mold surface; harder the surface more aggressive compound you will need. In some cases you might need 3 steps, aggressive compound, mild compound and then polishing compound.) STEP 2: Finish buffing entire mold with FK s #330: Mini Buff. FK recommends use of a 100% soft, lamb s wool finishing pad. CLEANING: STEP 3: Apply FK s #135-80: Polymer Mold Cleaner and Wax Remover. Spread, agitate and wipe while wet. For excessive wax buildup or residue, reapply #135-80, allow it to dwell for penetration, then agitate and wipe. Sometimes, 3 applications of # may be necessary. SEALING POROSITY: STEP 4: Apply one coat of #86: Seal Kote. Allow it to dry minutes and wipe lightly. STEP 5: Reapply another coat of #86, allow it to dry thoroughly and wipe gently. Let it sit for about 60 minutes. This will allow the polymers to set and bond to the entire mold. Then, wipe it lightly with a clean soft cloth. APPLYING MOLD RELEASE AGENT: STEP 6: Apply one of FK s Mold Release Waxes (#1000P: Hi-Low Paste Wax, #1165: Hi-Temp Extra Hard Premium Wax or #333MR: Blue Wax) in 5 separate applications. Wipe lightly after each coat and wait at least 30 minutes between each coat. STEP 7: After applying the final coat of wax, wipe, allow 30 minutes to set, and re-wipe. Pour the first part and release it. STEP 8: Reapply one more coat of wax, pour part and release it. Now the mold is ready for multiple releases, so proceed as in multiple cycles. NOTE: On tooling Gel Coat or Green Molds, FK recommends the use of at least 4 coats of #86 while following the above instructions. Give ample time for each coat to dry prior to wiping and reapplying. FINISH KARE PRODUCTS, INC. T: F:

15 PROCEDURE FOR STORING MOLDS When pulling molds for storage, FK recommends use of #331-21: Storage Wax. It offers protection during the storage period. To place mold back into service, wash the mold with soap and water and wipe. Then, follow the procedures outlined for New Molds or for Rejuvenating Old Molds. REJUVENATION OF OLDER MOLDS Any scar, imperfection or scratch that remains after sanding and polishing will carry through as an unsightly blotch and will mar the appearance of the finished part. Thus, sanding should be done meticulously and in sequence of finer grits. You should finish the final sanding preferably with 1200 grit or finer grit sand paper. To aid in detecting scratches during the repair process, occasionally wipe-down the area with a 50:50 mixture of IPA (Isopropyl alcohol) and water. The alcohol solution helps to remove any wax or fillers that may be hiding the finer scratches and blemishes. This way, you can see the true finish of the mold surface. FK recommends use of #780: Sand Lube* for wet sanding. We recommend to start off with 600 grit sand paper for wet or dry sanding using a rubber block. For wet sanding, wet out the sand paper using a solution made with FK s #780. Use a rubber squeegee to keep the mold dry. Finish sanding with 1200 or higher grit sand paper. ANTI-STAT RELEASE SYSTEM FK has three main products with anti-static properties: #69 AS: Anti-Stat Mold Cleaner & Stripper #1000L AS: Anti-Stat Hi-Low Liquid Wax #1000L-28 AS: Anti-Stat Sprayable HD Mold Release Wax Benefits of Anti-Stat products: 1. Definite neutralization of static charge. 2. No tracking or clinging of dust particles so it is easy to blow off dust 3. Assured positive charge on molded parts resulting in cleaner, dust-free parts. * Add 2oz. of #780 to ½ gallon of water. Use of #69AS in cleaning molds will eliminate dust and particle attraction to molds due to build up of static electricity. It will zap the charge when applied after buffing or polishing. FINISH KARE PRODUCTS, INC. T: F:

16 PREVENTATIVE MOLD MAINTENANCE Annually, a great deal of production time is lost due to wax buildup, surface tension and dullness in particularly tight areas over the mold. Subsequently, crazing occurs and eventually parts are lost and there is a need for mold repair and rejuvenation. FK recommends using: #69: Mold Cleaner & Stripper or #80: Liquid Mold Cleaner or #135-80: Polymer Mold Cleaner and Wax Remover #1000P: Hi-Low Paste Wax and #1000L: Hi-Low Liquid Wax Processes given below prevent these problems and assist you in keeping your mold in production longer to get better productivity. This translates into reduced costs, better bottom line and increased profit. ONCE MOLD IS PROPERLY PREPARED ACCORDING TO PROCEDURES OUTLINED EARLIER (NEW MOLD PREPARATION OR REJUVENATION OF OLD MOLDS) AND MULTIPLE RELEASES CYCLE IS WORKING, PLEASE FOLLOW ONE OF THE APPROPRITE PROCESS OUTLINED BELOW: PROCESS 1: Apply #1000L: Hi-Low Liquid Wax to the mold over the paste wax when the part gets a little hard to pull between multiple releases. Use of #1000L will liquefy old wax and will reactivate it to make it a part of the mold release agent, thereby avoiding the wax buildup. Thus, the application of #1000L will reduce surface tension, keep the proper amount of Hi-Low Wax on the mold and will achieve problem free and easy releases. PROCESS 2: FK recommends reapplication of a Paste Wax or mold release agent, over the entire mold along with the application of Liquid Wax after 6-8 releases. Then revert back to use of only #1000L: Hi-Low Liquid Wax. Therefore, use of #1000L on a regular basis will deter wax buildup and most importantly surface tension by keeping a fresh coat of release agent on the surface for better & easy releases. PROCESS 3: The inevitable thing is that wax will builds up no matter what care or precautions you take. So, when wax build-up does take place, areas of dullness will appear and surface tensions will develop around deep corners, contours and radiuses and parts will become a little harder to pull. At this time redo the complete cleanup procedure to prepare the mold. Use either #69 or # to clean the mold thoroughly by agitating and wiping while wet. Two or three coats may be necessary. This will remove the wax build-up and reduce the surface tension. Then, apply 2 coats of #86 and 3 to 4 coats of Mold Release agent (either #1000P or any other paste wax or #135T) and put mold into production. Following these processes will assure prolonged mold use and will give trouble free and easy releases. Thus, the total work will be reduced and you will achieve more production with better profitability. FINISH KARE PRODUCTS, INC. T: F:

17 PRODUCT COMPARISON CHART FINISH KARE OFFERS THE MOST COMPLETE LINE OF MOLD PREP and MOLD RELEASE PRODUCTS CLEANERS: Finish Kare TR Meguiar s Rexco Specialty #69: Mold Cleaner & Stripper TR 210 NO COMPARABLE PRODUCTS #80: Liquid Mold Cleaner NO COMPARABLE PRODUCTS #135-80: Polymer Mold Cleaner and Wax Remover MOLD SEALANT: TR 905 NO COMPARABLE PRODUCTS #86: Seal Kote NO COMPARABLE PRODUCTS MOLD RELEASE AGENTS: #135T: Polymer Release Agent TR 900 NO COMPARABLE PRODUCTS #135ER: Urathane Release Agent #333MR: Blue Wax TR 102/ TR 108 MGM 16/88 #888: Max Mold Release Paste Wax #8 #1000P: Hi Low Paste Wax TR 104 NO COMPARABLE PRODUCTS NO COMPARABLE PRODUCTS Mold Release Wax Partall Hi-Tem Wax # : Brush Gel Coat Release Paste Wax NO COMPARABLE PRODUCTS #1006: Pre-Release Deterrent Paste Wax NO COMPARABLE PRODUCTS #1165: Hi-Temp Extra Hard Premium Wax NO COMPARABLE PRODUCTS #1000L: Hi-Low Liquid Wax TR 214 NO COMPARABLE PRODUCTS #1000L-28: Sprayable HD Mold Release Wax COMPOUNDS & POLISHES: NO COMPARABLE PRODUCTS #103: Extra HD Cleaner NO COMPARABLE PRODUCTS #600: White Fine Rubbing Compound (Paste) NO COMPARABLE PRODUCTS KantStik Mold Cleaner Honey Wax & H. Plus Wax Honey Wax & H. Plus Wax Golden Wax Liquid #440-5: Polishing Compound TR 311 M0164 NO COMPARABLE PRODUCTS #923: Micro Polishing Compound M0364 NO COMPARABLE PRODUCTS #330: Mini Buff TR 308 NO COMPARABLE PRODUCTS OTHER WAXES & PRODUCTS: #68: Edge Wax TR 110 NO COMPARABLE PRODUCTS #604B: Mold Sealer & Release Wax NO COMPARABLE PRODUCTS #626: Polymer Hat Wax TR 111 NO COMPARABLE PRODUCTS KantStik EP #332: Hand or Spray Interphase Release Wax NO COMPARABLE PRODUCTS #PB-1:Traffic Wax TR 504 NO COMPARABLE PRODUCTS #64: PVA Clear / #65: PVA Blue NO COMPARABLE PRODUCTS KantStik C #67: PVA Green NO COMPARABLE PRODUCTS Partall Film # 10 #PV-6: Film Agent NO COMPARABLE PRODUCTS * Please note that this comparision is not based on actual chemical analysis, but according to comparative use properties. 17

18 For product inquiries, questions or sample requests, please contact: FINISH KARE PRODUCTS, INC Floradale Ave., So. El Monte, CA USA T: F: Please feel free to copy any of the procedural pages for shop personnel. Hang in the work area for easy reference and better demolding. 18