ESC Molding Guidelines

Compression Molding 
Quantum Composites’ Engineered Structural Composite (ESC) 

This bulletin offers suggestions as general guidelines for the successful molding of ESC Materials.  Since each component and application is unique, your own experience and equipment requirements will ultimately dictate the specific conditions and optimum cycle that will produce the best part.  Please call Quantum Composites to discuss molding in more detail. 

1. Clean mold thoroughly.  Apply a uniform thin coating of a mold release.  *(Note:  Once the mold is conditioned, only periodic reapplications are required.)
2. Adjust mold temperature to 270-320°F (132-160°C).  285°F is a good starting point. 
3. Adjust molding pressure on the material to 1000-2000 psi (70-140 kg/cm).             
4. Remove protective film completely from both sides of the ESC. 
5. Cut mold charge so the ESC covers approximately 80% of the mold area and is about 105% of the calculated part weight.  Start with a simple and easy charge pattern. 
6. Load material into mold and close the mold.  A final press closing speed of 5 – 10 sec./in. is recommended. 
7. Cure time is dependant on part thickness, mold temperature and ESC used.    (Approximate cure time for 1/8” thickness will be 2 – 3 minutes) 
8. Remove part from mold.   
9. Clean up mold and begin again. 

*Suggestions: Stoner S497 or E455 Mold Release -  Telephone No. 717 786 7355
 More detailed information is available upon request.

Lytex® Molding Guidelines

Compression Molding
LYTEX® Epoxy Engineered Structural Composite (ESC)

Molding of LYTEX epoxy ESC is similar to the molding of other highly filled glass fiber ESC’s. However, because of the high fiber loading and epoxy chemistry, there are a few important differences. This bulletin offers suggestions as general guidelines for the successful molding of LYTEX. Since each component and application is unique, your own experience and equipment requirements will ultimately dictate the specific conditions and optimum cycle that will produce the best part. Please call Quantum Composites to discuss molding in more detail.

1. A summary of the procedure for compression molding LYTEX epoxy ESC follows:
2. Remove enough LYTEX from cold storage for one day's usage. Allow it to warm to room temperature.
3. Clean mold thoroughly. Apply a uniform thin coating of a mold release.* (Note: Once the mold is conditioned for LYTEX only, periodic reapplications are required.)
4. Adjust mold temperature to 270-325°F (132-163°C). 300°F is a good starting point.
5. Adjust molding pressure on the material to 1000-2000 psi (70-140 kg/cm). 
   Note: Excessive pressure can be detrimental.
6. Remove protective film completely from both sides of the LYTEX.
7. Cut mold charge so the LYTEX covers approximately 80% of the mold area and is about 105% of the calculated part weight. Start with a simple and easy charge pattern.
8. Preheat LYTEX quickly to 140-190°F (60-90°C). Dielectric preheat is best for glass-filled LYTEX. Oven preheat of separate pieces for up to 2 minutes at 200°F is feasible. Do not attempt to use microwave or dielectric preheat with LYTEX containing carbon fiber.
9. Load material into mold and close the mold.
10. Cure for 3-15 minutes, depending on part size and temperature. A smaller part (about 1/8" thick) may require 3-5 minutes for full cure, while a larger part may require 10-15 minutes. Cure is dependent on mold temperature and part thickness.
11. Remove part from mold. Because of low shrinkage and high strength, the part may fit snugly in the mold.
12. Clean up mold and begin again.
13. Re-wrap unused LYTEX and return to cold storage.

*Suggestions: Stoner S497 or E455 Mold Release - Telephone No. 717 786 7355
More detailed information is available upon request.
®LYTEX is a registered trademark of Premix, Inc