Mould sealer for tooling boards Mikon® 399 MC

Best quality and high process reliability in model and mould construction

 

The Challenge

Tooling boards of various densities are commonly used in model and mould construction. These materials need to be treated with a sealing compound prior to the application of mould release agents in order to avoid absorption of the release agents by the pores.

Traditionally, moulds have been sealed by multiple layers of a multi-component automotive coating. This procedure was very time-consuming and laborious as the mould had to be grinded and polished after each single application. The adhesion strength of release agent to the coated surface was rather low and the coating layer exhibited a poor chemical resistance against both the release agent and the phenolic or epoxy resins used for the manufacturing process. Hence, moulded parts were of low quality.

Although preparation time was significantly reduced, the more recently developed single-component wax-based mould sealers required equally high efforts for processing as a complete sealing of all pores was only possible with 20–30 coating layers. This build-up was particularly problematic for the manufacturing of parts that were supposed to exhibit a maximum accuracy of fit.

In summary, the overall process reliability for both sealing systems was very low.

Our Solution

The team of Münch Chemie International GmbH analysed the manufacturing process in model and mould construction in detail. Our chemists paid particular attention to board
materials, resins and release agents as well as chemical and physical interactions correlated to the most common processing conditions. Based on the analytical findings, a range of raw materials suitable for homogenous sealing of tooling boards was selected.

An innovative single-component mould sealer, available in colourless or black version, was formulated which was easy to apply onto the boards and exhibited fast curing times. First results on the laboratory scale were promising: A very smooth homogenous surface was obtained with only two layers of the new mould sealer named Mikon® 399 MC which could be applied either by spraying or painting / wiping. Microscopic analyses proved that all pores were evenly sealed despite the coating thickness being only ≤ 1 µm. After drying / curing at room temperature for approximatively 5 minutes this formulation exhibits unique properties, such as a high gloss finish, without the need for any sanding or polishing. Furthermore, subsequently applied solvent- or water-based semi-permanent release agents exhibited very good bonding on the sealer.

Additional plant trials confirmed these results and further demonstrated that the straightforward handling without the need for any preparation time or post-processing was particularly advantageous. Upon application of the new sealer in combination with release agents from our Mikon® product series both the overall process reliability and quality of moulded parts with regard to surface quality and accuracy of fit remarkably increased. Due to its high
resistance against chemical and physical impacts the new sealer allowed for several
consecutive demouldings for the first time.

In conclusion, Münch Chemie International GmbH is the first manufacturer of release agents across the globe to offer customers an innovative easy-to-handle mould sealer for tooling boards which guarantees a high process reliability and quality, thereby allowing high cost savings.

 

Your Benefits

  • Low material consumption (approx. 25 g/m² Mikon® 399 MC instead of 30-40 g/m² wax-based mould sealer)
  • Minimal effort (ready-to-use product, max. 2-3 coating layers, fast drying/curing time, no laborious after-treatment required after application of sealer)
  • Application via all commonly used methods such as spraying, painting or wiping
  • High resistance against increased temperature and chemicals
  • Both colourless and coloured mould sealer available
  • Significantly improved process reliability (mould sealer perfectly matches semi-permanent release agents from Mikon® product series)
  • Enhanced overall quality of moulded parts (increased surface quality, maximum accuracy of fit)
  • Excellent value for money
  • Increased overall efficiency

 

Concrete Example

The following example concretely illustrates the numerous benefits for a company in the rotor blade production of using our innovative mould sealer for tooling boards Mikon® 399 MC, compared to wax-based sealers:

→ Based on a rotor blade measuring 5 m. x 70 m., corresponding to a surface of 350 m²

 

1) Traditional application method of release agents on a master model with wax-based sealer and semi-permanent release agent

First step: Application of the sealer

20 layers of wax-based sealer are applied on the master model, corresponding to a consumption of hard wax of approx. 0.03 kg/m² and 210 kg for the entire model. At a price of approximately 8 €/kg it amounts in total to 1680 € of wax-based sealer.

For the sealing are 6 workers employed during 10 working hours, corresponding to 60 hours of plain working time. On the basis of a production worker’s wage of approximately 25 €/hour, the labour costs amount in total to 1500 €.

 

Second step: Application of a semi-permanent release agent

After the sealing, the customer applies a semi-permanent solvent-based release agent on the master model. 20 kg of release agent at a price of 25 €/kg are needed and 2 workers are employed during 10 hours for the application:

- Material costs (release agent): 500 €

- Labour costs for this step (2 workers): 500 €

With this method, only one demoulding is possible and energy has to be invested to remove the release agent film from the mould surface, which has been broken by the model.

Therefore grinding and polishing costs must be added. Furthermore a new adequate release agent film has to be applied.

In the best possible conditions, these steps correspond to an additional charge of approx. 1000 €.

 

Total costs

Material costs (wax-based sealer): 1680 €
Material costs (semi-permanent solvent-based release agent): 500 €
Labour costs (sealer): 1500 €
Labour costs (release agent): 500 €
Additional charge (preparing the mould for the next casting):  1000 €
  5180 €

 

2) Innovative application method with Sealer Mikon® 399 MC and an environment-friendly semi-permanent water-based release agent from the Mikon® series.

The same master model with a surface of 350 m² will be taken as an example.

Through the outstanding sealing properties of Sealer Mikon® 399 MC, only 2 layers of sealer and 2 layers of water-based release agent from the Mikon® series are necessary.

 

First step: Application of the sealer

Only 1 worker is employed during 10 hours for the application and the sanding of 2 layers of Sealer Mikon® 399 MC. The labour costs for this processing step amount to 250 €.

The quantity of material needed for this step (2 layers) is approximately 17.5 kg (0.025 kg/m²), corresponding to 1050 € (approximately 60 €/kg).

 

Second step: Application of a semi-permanent release agent

2 workers are required for applying and polishing the 2 layers of a semi-permanent water-based release agent from the Mikon® series. The labour costs for this processing step (corresponding to 10 hours in total) are 250 €.

The quantity of material needed for this step is approximately 17.5 kg, corresponding to 350€ (approx. 20 €/kg).

 

Total costs

Material costs (Sealer Mikon® 399 MC): 1050 €
Material costs (semi-permanent water-based release agent): 350 €
Labour costs (sealer): 250 €
Labour costs (release agent): 250 €
  1900 €

 

In conclusion, the innovative application method with Sealer Mikon® 399 MC and an environment-friendly semi-permanent water-based release agent from the Mikon® series generates considerable time and cost savings compared to the traditional application method with a wax-based sealer.

The total savings amount to approximately 3280 €, corresponding to 63.32 % of savings.

 

My name is Jörg-Henry Ehlers.

I am responsible for the areas of GRP / CFRP composites, wind energy, model and mold and would be pleased to advise you.

You can call me at +49 6201 9983 35 directly. You can also use the contact form.

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