Mold Release Coating

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  Mold Release Agents

  7:34:24 pm on Tuesday, 20 May 2008  2 Comments  

  Mold release agents have been used for decades. From vegetable oils to modern chemicals, they have come a long way. And still, regardless today’s technological breakthroughs, they don’t last very long. The longest being about 50 shots, these release agents must always be applied and re-applied.

  Mold Release

  Mold release (parting) agents aid in parts release. Yes, parts do come off more easily from the mold. But scrap parts can really slow down production. This is especially so when these scraps get stuck in the mold. Down mold, extrication and cleaning make production schedules difficult to keep to. Efficient mold release should be about fewer scraps and faster production timings.

  Mold Release Sprays

  Mold release sprays generally have the shortest lifespans. A spraying every 4 to 5 shots adds up to a lot if you do your calculations. Sprays also have a habit of contributing to airborne cross-contamination. This can transmigrate through unfiltered air circulation systems and spread to other rooms sharing the same system.

  Airborne transmigration contaminates all surfaces. It often requires that parts must be washed after fabrication. This form of transmigration can also build up in air vents and turbine blades.

  Mold Release Gels

  Mold release gels last a little longer. Still, these sacrificial coatings require steady hands and a certain measure of skill and experience to apply. Normally applied in double layers, the bottom layer is usually dark and the upper layer, white. When the color of the bottom appears during molding, it’s time to apply another upper coat.

  This color indicator system poses a problem of color pigment transmigration. Some plastic are more sensitive to color pigments than others. And if these pigments are fused with silicone, time must be spent washing the parts.

  Mold Release Stearates

  Mold release stearates are metallic powders. These must be used carefully away from eyes and skin and, breathing in this stuff could cause real problems. You must use this carefully to avoid redness of eyes, burning skin, nervous disorder and fainting.

  The worrying thing about this stuff is prolonged exposure to it. Proper breathing equipment is advised and a good air ventillation system would really help. Also, remember to have some water nearby in case of eye or skin contact.

  Mold Release Semi-Permanent Coatings

  Mold release semi-permanent coatings speak volumes just by their name. They don’t really last. A lot of these coatings are water-based and less harmful than the others. But they don’t last for long. Around 50 shots is the most these coatings will do.

  Again, time and effort in application might not justify the operating costs. And there’s also a question of transmigration rates. Water-based coatings don’t usually have very strong chemical structures. Chipping, flaking and peeling might also have to be considered. The reduction in transmigration rates are in comparison to common mold release agents.

  Mold Release Permanent Coatings

  Mold release permanent coatings used to refer to electroplated coatings and vapor deposition coatings. While these are tough coatings, mold release agents have to be used because of poring. These coatings are known for their hardness, not smoothness.

  And while there is some improvement in surface texture and appearance of molded parts, sticking can still affect overall parts release. Nonetheless, these coatings are very hard and often serve their intended purpose.

  Mold Release True Smoothness

  Mold release true smoothness is achieved at microscopic levels. When tiny pores and etch marks are covered, true smoothness is attained. There are some microscopic coatings that deliver true smoothness. But only one such coating can last for a long, long time.

  Mold releasing agents and coatings aid in mold release. But they don’t last for long. Time is wasted on re-applications. Transmigration and cross-contamination may be problematic. Safety and health issues must be considered. These factors frustrate production schedules.

  Nanomouldrelease is different. It lasts between 5,000 to more than 100,000 production cycles. And it’s only 0.2 microns thick. By comparison, it lasts a lot longer than mold release agents.

   

• Mold Release Coating Breakthrough

  2:10:54 am on Friday, 9 May 2008    

  Mold Release Coating breakthrough: the microscopic mold release coating that stops sticking and mold fouling. This coating replaces mold release agent technology. It makes it unnecessary to ever use parting or release agents. Unbelieveable?  Read on.

  It reduces material & labour costs, production time, down-mold & stoppage time, cleaning & repair time, material wastage, failure rates and utility bills.. Gone are the days of standing around the molding machine and wondering what went wrong.

  It increases production speed & efficiency, resin & air flow rate, uninterrupted process & flow, cosmetic value and dimensional integrity. More parts with less work every day!

  Mold Release Micro Coating

  The use of mold release and parting agents make it difficult to meet high quantity orders at shorter lead times. Time is money… and it waits for no one. The ever increasing pace of business demands a more efficient way of doing things. A mold release micro coatings dramatically shortens lead time.

  Much time and effort are required in applying mold release and parting agents. But such chemicals are not always reliable. Parts still stick to, or get stuck in, molds and mold fouling is often produced. Cross-contamination is a major issue. A single mold release micro coating can last thousands and thousands of cycles.

  Mold Release Coating Benefits

  With a permanent mold release coating, there is no hassle of constantly re-applying liquids, gels, waxes and powders. There is also no need to install an expensive air flitration/exhaust system. Many companies have discovered that silicone can be carried to every room that shares the same unfiltered central air-conditioning system. A mold release coating eliminates problems associated with air borne cross-contamination.

  The money spent on a single mold release coating is nothing compared to the money spent on buying a lot of mold release and parting agents. A factory that we visited had 30 molding machines. 5 of those machines had sticking problems. Each of those 5 machines used an average of 6 canisters of mould release agents per day. 30 canisters of mould release agents had to be used each day. This amounts to 840 canisters for every 4 weeks of operation. That’s a lot of money.

  Completely inert mold release micro coatings produce inert residue during wear and tear. And if they last a long time, this means that transmigration from coating to part is very low. So low that this transmigration can only be calculated and cannot be observed. This means that fabricated parts do not need to be washed before painting, bonding or transfer molding. The problems associated with de-lamination are also solved.

  Mold Release Coating Durability

  Applying mold release or parting agents also requires a measure of skill and experience. Not having to always search for the correct type of mold release or partings agents saves both time and money. And even with the best mold release agent, the desired results only last a few cycles.

  Mold release micro coatings fit perfectly onto substrate surfaces. It does so by entering and filling up all pores and etch marks. The adhesion strength of micro coatings is far superior to coatings that coat over pores and etch marks that still have pockets of air in them.

  Ductile net-like mold release micro coatings can weather temperature fluctuations and abrasion. Ductility lessens the impact of abrasive forces and the net-like structure facilitates out-gasing. Heated materials release gases that de-laminate coating seals and laminations. The ability for a coating to out-gas prevent de-lamination.

  A good mold release micro coating should be able to last at least a thousand cycles. This would justify the transition from release agents to release coatings. Gel and wax coatings work well but they only last a few cycles. The better ones last a little longer and don’t cross-contaminate parts. But the time, money and effort in applying such coatings doesn’t always make financial sense. A good mold release micro coating, in my opinion, is the wiser mold release alternative.

   

• Mold Preservation Treatment

  4:14:13 am on Thursday, 8 May 2008    

  Mold Surface Treatment

  Mold Surface Treatment traditionally involves grinding, polishing or plating. Such treatments were aimed at smoothening substrate surfaces but poring remained an issue. Substrate surface pores in mold cavities are the places where sticking primarily occurs. While results are improved, sticking remains unresolved.

  Surface Treatment with Nanotechnology

  Nanotechnological advances in chemistry allow for molecular alteration. Particles may be induced to form task-specific molecular structures. In the case of Nanomouldrelease, particles are arranged in a matrix resembling a mesh-like netting. Spaces within this netting allow gas to traverse it but prohibit passage to water and oil.

  Nanomouldrelase is stored in a ethanol base solvent cage. Upon application, it spreads over and enters into all topographical features of the substrate surface. All microscopic pores and etch marks are filled. Then as the ethanol evaporates, physical laws of attraction and repulsion compel component particles to self-arrange into a net-like structure.

  Mold Dimensional Integrity

  This net-like structure measures 100 to 200 nanometers in girth. Dimensional requirements therefore remain well within even the strictest engineering tolerances. Miniature profiles and detailing are unchanged and micro burring does not occur.

  Corners and non-slip texturing are also unaffected by Nanomouldrelease. In the case of non-slip texturing, the fabricated part appears shinier. This is because of the absence of cobwebbing and other minute imperfections caused by sticking. Matte finishes remain largely unchanged as the non-glossy effect is achieved through manipulation of speculary reflected light angles.

  Surface Non-Reactivity

  Colorless and completely inert, Nanomouldrelease forms a second skin that provides excellent dry non-stick lubricity. It also resists corrosion and does not interact with other substances to form mold fouling. Build ups tend to occur with stoppages in operation. In wells, valves, sprues, gates and nozzles, build ups can be easily removed. This is because there are no pores or etches for melt to secure itself onto.

  Inert surfaces also possess low surface energy. This facilitates excellent air flow much needed in mold release processes. If air cannot find smooth passage over such surfaces, a vacuum (sticking) force factors in. Inert surfaces also possess good hydrophobic and lipophobic properties.

  Mold Surface Preservation

  Nanomouldrelease prolongs the operational lifespan of substrate surfaces. The same corrosion barrier that it provides also prevents the onset of abrasion. Abrasion is a process that requires one material to rub against another material. When the surface of one material is smooth, abrasion is greatly reduced.

  Tiny pores and etch marks exist on even the smoothest of uncoated surfaces. Corrosion and abrasion can increase the size of such features in a very short time. As these features get larger, the rates of corrosion and abrasion accelerate. Nanomouldrelease effectively prevents corrosion and greatly retards the acceleration of abrasion.

  Lasting Mold Preservation

  When used as a mold coating, Nanomouldrelease has been known to last more than 100,000 cycles. This is achieved without damage to the mold. With continued correct use of Nanomouldrelease, a mold would have an indefinite lifespan. Certain mold release and parting agents can also achieve this. But the time, effort and money to use such agents may not justify balance sheets.

  Accomplishing more projects a year with less expenditure on materials, utilities and manpower would be the best way to run a business. Nanomouldrelease does all this.

   

• Nano Mould Release

  7:17:10 am on Monday, 14 Apr 2008    

  Nano Mould Release is also known as Nanomouldrelease. It has solved a host of sticking problems in Plastic Parts Fabrication by facilitating good mould release at nano level. It does so by providing dry ainti-stick lubricity without using mold release agents. But the success of Nanomouldrelease is not only limited to Plastic Parts Fabrication.

  Outdoor Signage

  Nanomouldrelease efficiently blocks off more than 95% UV light. When it is applied onto colored materials or paint, it can make colors last for years and years. Even acrylics, which are damaged by exposure to UV light, can retain their glass-like appearance for a much longer time.

  Electroplated Ornaments

  Nanomouldrelease forms a protective barrier over electroplated surfaces. Acid rain cannot tarnish or corrode coated electroplated surfaces. The nano matrix structure that provides good release for moulds also provides protection from corrosion and oxidization.

  Micro Electronic Components

  Fine detailing in miniature electronic components cannot be laminated because of heat buildup. Such conponents are heat-sensitive and must “breathe” during operation. But oxidization is a major issue.

  Nanomouldrelease has out-gassing capabilities that allow heat to escape through its protective anti-oxidization barrier. It is also chemically (electrically) non-reactive which makes it ideal for low-voltage electronics.

  Medical Trays and Surfaces

  Nanomouldrelease has In Vitro Cytotoxicity Assay certification. This means that it can be used on medical trays and sterile surfaces. Further details can also be found in the its MSDS and ROHS certifications.

  Miniature Instruments, Gears and Cogs

  Miniature parts require very tight precision engineering tolerances of between 1 to 3 microns. Nanomouldrelease meets these requirements with its sub-micronic dimensions. Its low surface energy and dry anti-sticking lubricity also means that such parts do not need to be lubricated.

  Nanomouldrelease is the peerless nano mould release solution. It remedies mould release problems at root cause: nano level. 

   

• Non-Stick Mold Coating

  8:02:17 am on Sunday, 13 Apr 2008    

  Non-stick mold coatings are usually not stable at operating temperatures above 210 degrees C. These generally contain PTFE or other like substances, all of which have a Tg (Glass Transition Temperature) point that begins from 210 degrees C and above.

  Tg refers to a point in temperature where the physical attributes of substances change from glass-like to rubber-like states. When this happens, transmigration and cross-contamination become serious issues. As such, non-stick mold coatings are only relevant at lower temperatures or, where transmigration and cross-contamination do not matter.

  Anti-Stick Mold Coating

  An anti-stick mold coating solution is a viable, efficient alternative. Most of these coatings do not use PTFE and can withstand higher operating temperatures. However, most of these types of coatings are a few microns thick and are structured as laminates.

  Engineering tolerances (measurement allowances) generally fall below 5 microns in total width. This means that a coating should not exceed 2.5 microns. Few coatings are thinner than 3 microns.

  Coating laminates do not perform well at high, fluctuating temperatures. Gasses released from heated coated surfaces accumulate and pressurize. Such pressurized gasses de-laminate (push off) the coating and destroy its adherence.

  The Proven Anti-Stick Coating

  Nanomouldrelease is the proven solution to sticking problems. It is less than a quarter of a micron thick and is gas permeable. It works reliably through a good range of temperature (-50~400 degrees C) and is not chemically reactive.

  This coating system also possesses excellent hydrophobicity (water repulsion) and provides dry lubricity without the use of PTFE. Its lipophobicity (oil repulsion) also ensures that oil cannot be absorbed into coated surfaces.

  Reliability That Lasts

  Nanomouldrelease can last for thousands of production cycles. It is able to do so because of both its physical and chemical structure. Physically, it is able to enter every pore and etch mark on a surface. This total coverage leaves nothing for substances to adhere to.

  Nanomouldrelease is also completely inert (chemically non-reactive). This means that it cannot be chemically worn down in chemical and heated production environments. This also means that it does not chemically bond with other substances or constitute to the creation of mold fouling.

   

• Micro Release Technology

  8:50:38 am on Saturday, 12 Apr 2008    

  The technology of Micro Release refers to the varying states where substances can or cannot procure footholds upon substrate surfaces at microscopic levels. Sticking and adhesion strength are dependant on the cumulative (summed up total) states of micro release, like the numerous strands of fiber that make constitute a rope.

  Good micro release occurs when substances cannot adhere to substrate surfaces. It is the ideal state whereby parts do not stick to, or get stuck in, molds. But to understand the precepts of good micro release technology, one must first understand what brings about poor micro release.

  Poor micro release is due to 3 main problems: chemical bonding, vacuum bonding (luting effect) or physical anchoring. These can be easily rectified with by applying a micro barrier called Nanomouldrelease.

  Micro Scale Solution

  Nanomouldrelease is a state-of-the-art microscopic barrier coating. This super-thin coating is 100% chemically non-reactive and colorless. It effectively covers entire substrate surfaces, as well as all surface profiles such as poring and etch marks.

  This microscopic barrier provides excellent dry, anti-sticking lubricity. Its exceptional mesh-like infrastructure allows gases to pass through it while keeping out water and oil. This means that coating de-lamination cannot occur.

  Superior Releasing Properties

  Substrate surfaces that are coated with Nanomouldrelease achieve superior micro releasing properties. The cumulative micro release effect results in excellent parts release and decreased production cycle time. The smooth flow of resin and air over coated surfaces also ensures that resin isn’t tightly packed. 

  Nanomouldrelease’s chemical inertness also provides long-lasting releasing stability as it is unaffected by chemical corrosion. It’s dry lubricity also prevents the creation of chemical byproducts called mold fouling. Resin build-ups can easily be removed without the use of chemicals or special tools.

  Micro Molding

  Micro Release Technology is the ideal solution to the Micro Molding Industry. This industry faces severe problems with short molding, fisheyeing, blurring and deformed parts. To make matters worse, no mold release or parting agents can be used because of mold fouling and parts sticking caused by luting action.

  The anti-stick dry lubricity that Nanomouldrelease provides solves all these problems.

   

• Mold Release Coating

  9:02:43 am on Friday, 11 Apr 2008    

  Mold release coating nanotechnology is the new, revolutionary method of parts release. This parts release coating works efficiently on mold cavities, inserts, hot runners and can last thousands of cycles. And it has taken the plastic parts fabrication industry by storm.

  Mold Release Alternative

  Nanomouldrelease micro mold release coating is in a class of its own. It possesses excellent hydrophobic and lipophobic properties while, at the same time, providing corrosion resistant dry lubricity.

  This coating has been known to last more than 100,000 production cycles without using mold release or parting agents. This marvel of technology is the most effective alternative because it doesn’t need to be applied over and over again. Production time can be reduced by between 30% to 50%.

  Corrosion Resistance

  Nanomouldrelease micro mold release coating is 100% inert. This means that cannot be chemically eroded (worn down). It also does not, and cannot, react with other substances to produce mold fouling.

  Nanomouldrelease micro mold release coating is extrememly thin. At approximately 0.1 um (microns) in thickness, it resembles a mesh-like structure. This structure only allows entities at sub-molecular level to permeate it.

  In laymen’s terms, water and oil cannot pass through the spaces in this net-like structure; only gas can pass through it.

  Undetectible Transmigration

  Nanomouldrelease micro mold release coating is translucent (colorless) and cannot be chemically corroded. It’s rate of wear and tear is very, very low. Calculations put the wear rate at a maximum of 25 ppm plus\minus 25. The debris from wear is at particle level and can only be proven through calculation.

  Visit http://www.moldreleasenanotechnology.com. Discover for yourself how much has changed in the plastic parts fabrication industry today.