 These plastics are formed by chemical which

leave them in a relatively fixed state.

 Formed and ‘set’ in a single operation when a
chemical reaction leaves them ‘fixed’ in the
shape of the mold. They cannot be softened or
reformed when reheated.
 Although thermosets can withstand high
temperatures, excess heat will simply cause the
material to decompose.
 An egg yolk is a good analogy for this. When
a yolk is raw. It is in a soft liquid state. But if
it is heated, it becomes hard and is no longer
capable of becoming soft.
 Often used when a product needs resistance
to extremes in temperature, electrical
current, chemicals and wear.
 HISTORY
The first commercially available synthetic material, Celluloid (cellulose
nitrate), was invented in 1866 by John Wesley Hyatt as a replacement for
ivory for use in billiard balls. Since that time, scientists have continued
to develop new plastics to provide consistent material alternatives for
durable goods.

The first commercial thermoset plastic was developed by Dr. Leo

Baekeland in 1909.
It was a phenolic material trade named Bakelite. This thermoset
material offered the new benefit of being firmly set -- not changing its
shape, even under heat and pressure.
Bakelite was used extensively as an insulating material for handles on
cookware and irons, and later found its way into applications such as
telephone earpieces, electrical housings and connecting blocks. It was
also a key ingredient in many of the weapons used in World War II.
John Wesley Hyatt Dr. Leo Baekeland
 1872
Experiments with phenolic resin had actually preceded Baekeland’s
work, beginning the work of German Chemist Adolf von Baeyer, but
these trials had succeeded only in producing viscous liquids or brittle
solids of no apparent value. It was Baekeland who succeeded in
controlling the phenol-formaldehyde condensation reaction to
produce the synthetic resin.
1907
Bakelite, trademarked synthetic resin invented by Belgian-born
chemist Leo Hendrik Baekeland. The beginning of the modern
plastics industry is often dated to Baekeland’s first patent
application
1909
Baekeland made the first public announcement of his invention, in
a lecture before the New York section of the American Chemical
Society.
 1910
Baekeland had a semi commercial production operation established in his
laboratory.
1911
General Bakelite began operations in Perth Amboy.
1920’s
It was widely used in knobs, dials, circuitry panels, and even cabinets for
radios, and it was also employed in the electric systems of automobiles.
1927
Bakelite patent expired.
1930’s
Cast Bakelite, along with many other competing phenolic resins, enjoyed a
vogue in colorful costume jewelry and novelties. Bakelite faced competition
from other thermosetting resin such as urea formaldehyde and melamine
formaldehyde and new thermoplastic resin.
 PROPERTIES
Thermosetting plastics retain their strength and shape even when
heated. This makes thermosetting plastics well-suited to the
production of permanent components and large, solid shapes.
Additionally, these components have excellent strength attributes
and will not become weaker when the temperature increases.
Each type of thermosetting plastic has a unique set of properties.
Epoxies, for example, exhibit elasticity and exceptional chemical
resistance, and are relatively easy to cure. Phenolics, while fairly
simple to mold, are brittle, strong and hard. Because of their wide
range of characteristics, thermosetting plastics find use in an
extensive variety of applications, from electrical insulators to car
bodies.
 PROCESSES
Thermoset plastic products are typically produced by
heating liquid or powder within a mold, allowing the
material to cure into its hardened form. These
products can be removed from the mold even
without allowing it to cool. The reaction used to
produce thermosetting plastic products is not always
the result of heating, and is sometimes performed by
chemical interaction between specialized materials.
Typical types of thermosetting plastics are epoxies,
polyesters, silicones and phenolics.
 APPLICATIONS

Thermosets have found

applications in a wide
variety of fields including:
• electronic chips
• fibre-reinforced
composites
• polymeric coatings
• spectacle lenses
• dental fillings
 COMMON PROPERTIES AND
NAME NAME WORKING USES
CHARACTERISTICS
Epoxy resin Araldite Excellent adhesive Bonding,
(ER) qualities, low shrinkage, encapsulation.
strong when reinforced Laminating, surface
coating
Melamine Formica Waterproof, tasteless, Worktops,
Formaldehyde Melaware odorless, mark and scratch tableware, buttons,
(MF) resistant electrical insulation

Urea Aerolyte Good adhesive qualities, Electrical fittings,

Formaldehyde Cascamite stiff, hard, brittle, good paper and textile
electrical insulator coating, wood
adhesive
Polyester Orel Beetle Stiff, hard, brittle, resilient Panels for car bodies
Resin (PR) as laminated GRP, formed and hulls, casting,
without heat or pressure. embedding
 PROPERTIES AND
NAME WORKING USES
CHARACTERISTICS

Boat hulls, bodies and

Glass Strengthened by glass fibres; mats some structural
Reinforced of glass fibre being sandwiched components of high-
between layers of polyester plastics performance cars and
Plastics (GRP)
aircrafts
Carbon-Fibre Strong, lightweight, higher strength
Plastics (GFRP) to weight ratio, durable, very Modern bicycles, sailboats
expensive
COMMON NAME: Araldite
Many adhesives (glues)
are thermosetting plastics. A good
example is “Araldite” which is an
epoxy resin that hardens when a
second chemical is added (a
catalyst). It will bond most materials
including woods and metals as well
as some plastics.
USES: for bonding of other materials
PROPERTIES:
good electrical insulator
hard
brittle unless reinforced
resist chemicals well
 HISTORY
The invention of epoxy resin has undergone a long
period of time. As early as 1891, the German Lindmann
hydroquinone and epichlorohydrin with the reaction of
condensation into the resin and make use of anhydride
curing. But its value has not been revealed. In 1930,
Pierre Castan of Switzerland and the United States
SOGreenlee further study, with organic polyamines to
cure the resin, showing a very high bond strength, this
attracted attention. Generally, the epoxy resin can
contain alkenyl synthesis of the parent compound, can
also contain active hydrogen atoms from the parent
compound synthesis.
Epoxy is either any of the
basic components or the
cured end products of
epoxy resins, as well as a
colloquial name for
the epoxide functional
group. Epoxy resins, also
known as polyepoxides,
are a class of reactive
prepolymers
and polymers which
containepoxide groups.
Epoxy resin is more commonly known as a type
of glue that is fast-acting and bonds to nearly
any surface. Epoxy resin is also nearly
impossible to remove from an item so once you
use it you can be certain it will not come apart.
Epoxy resin can also be found in many other
useful products. Epoxy resin is very inexpensive
to purchase but its effects can last for several
years depending on its use. The following article
will share with you what the best applications
are for epoxy resin.
APPLICATIONS OF EPOXY RESIN
* Structural connections transferring high loads into
slim columns
* Fixing sanitary-ware to hollow masonry
* Holding down bolts for steel columns
* Tying back existing masonry facades to new steel
structures
* Dynamic applications: holding down machinery
* Fixing starter-bars for reinforcements
* Wall-tie replacements
Phenol formaldehyde resins(PF) or phenolic
resins are synthetic polymers obtained by the
reaction of phenol or substituted phenol with
formaldehyde. Used as the basis for Bakelite,
PFs were the first commercial synthetic resins
(plastics). They have been widely used for the
production of molded products including
billiard balls, laboratory countertops, and as
coatings and adhesives. They were at one time
the primary material used for the production
of circuit boards but have been largely
replaced with epoxy resins and fiber glass
cloth, as with fire-resistant FR-4 circuit board
materials.
 PROPERTIES (PHENOLIC
RESIN PHENOL FORMAL
DEHYDE)
The phenolic resin’s polarisability is 10-24cm3and Enthalpy of
vaporizationis 43.52 kJ/mol. It’s polar surface area is 9.23 Å2.
It has 1 H bond donor and 1 H bond acceptor. 72.5 °C is it‘s flash
point, 181.8 °C at 760 mmHg it’s boiling point and 0.614 mmHg at
25°C is it’s vapor pressure.
Phenolic resin has the color is Resin itself tends to be amber-
colored.
It has Wide variation depending on fillers and nature of resin.
It is Smooth and has lustrous surface.
Usually it seems hard and rigid, with good dimensional stability.
It may be brittle in thin sections with low impact strength.
It is very easy to mould.
Phenolic resin has Retain properties at freezing temperatures.
 The phenol formaldehyde have Improved strength
and dimensional stability and Improved impact
resistance and also cast resins.
Phenol formaldehyde wide range of molding
powders is available in which the composition of the
resin, fillers etc is varied to provide mouldings suitable
for many purposes.
It is good dimensional stability on heating up to
about 300 degree F Poor conductors of heat , so that
handles of pans etc stay cool to touch.
It can burn only with difficulty.
it is good electrical insulators, Laminated Plastics.
PRODUCTS
COMMON NAME: Formica or Melaware
Used in the production of
plastic laminates because of its smooth
surface and hygienic qualities.
PROPERTIES:
waterproof
odorless
mark and scratch resistance
USES:
worktops
buttons
electrical insulation
Melamine formaldehyde (MF) thermoset products became leading members of the
amino resin family, including urea and thiourea, because of superior properties.
MF resins were developed through the 1930s and 1940s in companies such as
American Cyanamid, Ciba and Henkel. Early applications, including fabric
impregnation and adhesives, were followed by the introduction of moulding
powders containing cellulosic fibres, pigments and fillers.
Outstanding properties such as clarity, stability to heat, light, chemicals, abrasion
and fire resistance met the great surge in domestic demand in the USA and
elsewhere in early post-war years. Principle among these were high-pressure MF
faced decorative laminate sheets, e.g. Formica® used for heavy duty surfacing. The
great variety of patterns and colours transformed kitchens, cafés, ships and trains
into easily maintained aesthetically enhanced surroundings.
The development of MF fine faced chipboard allowed rapid production of light duty
decorative panels for furniture application in very high volumes which continues
today.
Another great impact was seen in MF moulded domestic table and kitchenware
where attractive durable products, e.g. Melaware, enhanced family life.
The many valuable applications of MF derivatives include adhesives, paints,
electrical mouldings and glass reinforces substrates.
 Laminate flooring, countertops, cabinetry, surface coatings, textile finishes,
paper processing and bonding are some of the areas where melamine
formaldehyde resins have excelled and continue to be widely used today.
Hexion is an expert in melamine chemistry with resins and additives serving
these markets and many more.
Our melamine resin technology is versatile and adaptable. Most of our MF
resins are highly customizable allowing our skilled technical service team to find
the perfect fit for your application.

Melamine resins are divided into two primary categories:

Methylated melamine formaldehyde resins have been etherified to varying
degrees and provide excellent stability even at very high solids content. This
makes them a prime choice for use in coating, crosslinking, textile, nonwoven
and papermaking applications.
Methylol or non-methylated melamine formaldehyde resins are typically used
in decorative laminates, composites and other water-based applications. Our
resins are adaptable to a wide variety of system parameters and, when cured,
are colorless, durable, and solvent resistant.
 Advantages
Easily coloured (unlike Phenolics). Taste and odour free. Good
resistance to solvents - stain resistant in general, although dependent
upon filler choice. Electrical properties relatively unaffected by high
humidity (unlike Phenolic). Self-extinguishing.

Disadvantages
Inferior to Phenolic in dimensional stability in hot dry conditions. More
expensive than Urea or Phenolic. Limited resistance to concentrated
acids and alkalies.

Applications
Impact resistant crockery (e.g. for hospitals and picnics), toilet seats,
pan handles and knobs, stain and cut resistant decorative laminates.
An alkyd is a polyester modified by the
addition of fatty acids and other
components. They are derived from polyols
and a dicarboxylic acid or carboxylic acid
anhydride. The term alkyd is a modification
of the original name "alcid", reflecting the
fact that they are derived from alcohol and
organic acids. The inclusion of the fatty acid
confers a tendency to form flexible coating.
Alkyds are used in paints and in moulds for
casting. They are the dominant resin or
"binder“ in most commercial “oil-based“
coatings. The original alkyds were
compounds of glycerol and phthalic acid sold
under the name Glyptal.
 PROPERTIES
Good weathering properties and are important
ingredients in many synthetic paints due to their
versatility and low cost.
One of the important attributes of alkyd resins is their
good compatibility with many other coating polymers
Very long emulsified oil-drying alkyds are also added to
synthetic latex house paints to improve adhesion to
chalky painted surfaces, whereas medium to short oil
alkyd resins are sometimes blended with silicone resins
with high phenyl content for air-dried or baked coatings
to improve heat or weather resistance
COMMON NAME: Aerolyte or Cascamite
Used in homes as an adhesive
resin in pressed wood products
PROPERTIES:
good adhesive qualities
stiff, hard and brittle
good electrical insulator
USES:
electrical fittings
paper and textile coating
wood adhesive
 The first patent on the condensation
product of urea with formaldehyde was by Hans
John in about 1920 but he used no catalyst. F
Pollak and his co-workers in Vienna used a
variety of catalysts and took out a number of
patents between 1920 and 1924. One of which
was for a glassy transparent resin which was
given the name Pollopas. Their efforts were
directed towards the so-called ‘organic glasses’
but this was not achieved until much later by
thermoplastics materials, especially acrylics.
Goldschmidt and Neuss in Germany
also worked on urea formaldehyde but the first
commercially successful thermosetting moulding
material was produced by the British Cyanides
Co. – based on a mixture of thiourea and urea
formaldehyde in 1928.
I G Farben developed urea
formaldehyde especially as adhesives and stoving
lacquers with patents in 1925 and 1928. In 1933
the various firms making urea formaldehyde
materials agreed to exchange patent rights in
order to avoid possible disputes and rapid
development followed.
 Urea-formaldehyde, also known as urea-methanal, so named for its common
synthesis pathway and overall structure,[1] is a non-transparent thermosetting
resin or plastic. It is produced from urea and formaldehyde. These resins are
used in adhesives, finishes, particle board, MDF, and molded objects. UF and
related amino resins are a class of thermosetting resins of which urea-
formaldehyde resins make up 80% produced globally. Examples of amino resins
use include in automobile tires to improve the bonding of rubber to tire cord, in
paper for improving tear strength, in molding electrical devices, jar caps, etc

PROPERTIES
Urea-formaldehyde resin's attributes include high tensile strength, flexural
modulus, and a high heat distortion temperature, low water absorption, mould
shrinkage, high surface hardness, elongation at break, and volume resistance.
Index of Refraction = 1.55
 PROPERTIES
Urea-formaldehyde (UF) products (also called aminoplasts) are highly cross
linked thermosetting, rigid, crystalline-like polymers 1. The UF resins are noted
for their high strength, cost effectiveness and fast cure. In fact, UF resins are
some of the fastest curing resins available. At elevated temperatures, they can
be cured in as little as two seconds.

A large portion of UF resins are consumed by the wood products industry. In

fact, UF resins are the most popular adhesives for particleboards. The popularity
of urea-formaldehyde resins as the main adhesive for wood products has
several reasons, including low cost, ease of use under a variety of curing
conditions, versatility, low cure temperature, resistance to mold formation,
excellent thermal properties, lack of color of the cured product, and excellent
water solubility of the (uncured) resin.
Due to toxicity concerns from health and environmental agencies and customers
(formaldehyde is a suspected carcinogen), the UF industry has developed new
urea-formaldehyde resins with very low formaldehyde release. Two well known
low emitting resin systems are Hexion's EcoBindTM and Arclin's E-Natural.
These resins were engineered to emit at or below naturally occurring levels
while maintaining comparable performance.
 APPLICATIONS

Urea-formaldehyde resins find applications in adhesives, coatings, laminatings,

and moulding compositions. More than 1 million metric tons of urea-
formaldehyde (UF) resin is produced annually.2 This comprises about 80% of all
amino resins produced worldwide. More than 70% of it is consumed by the
wood industry for bonding particleboards (61%), medium-density fiberboard
(27%), and hardwood plywood (5%). It is also used as an adhesive for decorative
laminate applications (7%). Other applications include wet laid fiberglass mats,
air filtration, coated and bonded abrasives.

Due to the lack of moisture resistance, UF wood adhesives are mainly used for
the manufacture of wood products intended for interior use only.
A polyamide is a macromolecule with repeating units
linked by amide bonds.
Polyamides occur both naturally and artificially.
Examples of naturally occurring polyamides are
proteins, such as wool and silk. Artificially made
polyamides can be made through step-growth
polymerization or solid-phase synthesis yielding
materials such as nylons, aramids, and sodium poly
(aspartate). Synthetic polyamides are commonly
used in textiles, automotive applications, carpets
and sports wear due to their high durability and
strength. The transportation manufacturing industry
is the major consumer, accounting for 35% of
polyamide (PA) consumption.
 PROPERTIES
Polyamides (PAs) are produced either by the
reaction of a diacid with a diamine or by ring-opening
polymerization of lactams.
They are either all aliphatic or all aromatic.
The aromatic polyamides, often called aramids,
have higher strength, better solvent, flame and heat
resistance and greater dimensional stability than the
all aliphatic amides but are much more expensive and
more difficult to produce.
PRODUCTS
COMMON NAME: Orel or Beetle
Used in sheet molding
compound, bulk molding compound and
the toner of laser printers.
PROPERTIES:
stiff, hard and brittle
resilient as laminated GRP
formed without heat and
pressure
USES:
panels for car bodies and boat
hulls
casting
embedding
 HISTORY
Unsaturated polyesters derive from the 1933 patent of Carleton Ellis.
Commercial development of polyesters for moulding began in the USA in 1941
with the introduction of a heat curing alkyl casting resin. This was followed by a
low pressure laminating resin (CR-39) based on allyl diglycol carbonate and used
for glass fabric reinforced radomes for aircraft.
In 1946 polyester resins containing styrene were used with a catalysed peroxide,
enabling cure at room temperature – the so-called ‘cold cure’ system. Such
plastics were also transparent to radar and found immediate use for wartime
applications. GRP (glass reinforced polyester) laminates later found extensive
use in the manufacture of boat hulls, road transport vehicle bodies and building
applications.
 Polyester resins are unsaturated synthetic resins formed by the reaction
of dibasic organic acids and polyhydric alcohols. Maleic Anhydride is a commonly
used raw material with diacid functionality. Polyester resins are used in sheet
moulding compound, bulk moulding compound and the toner of laser printers.
Wall panels fabricated from polyester resins reinforced with fiberglass — so-
called fiberglass reinforced plastic (FRP) — are typically used in restaurants,
kitchens, restrooms and other areas that require washable low-maintenance
walls.
Polyester is a category of polymers that contain the ester functional
group in their main chain. As a specific material, it most commonly refers to a
type called polyethylene terephthalate (PET). Polyesters include naturally
occurring chemicals, such as in the cutin of plant cuticles, as well as synthetics
through step-growth polymerization such as polybutyrate. Natural polyesters and
a few synthetic ones are biodegradable, but most synthetic polyesters are not.
This material is used very widely in clothing.
 COMPONENTS
Pigments -The material is composed of pigments that are very similar
to those used in other pavement markings. The pigments are used to impart
color, hiding and other desirable properties, like all other markings. However,
these pigments are pre-ground prior to being blended into the resin.
Resins -The marking has polyester resin that is mixed with a reactive
solvent, a styrene compound. Normally, solvents are expected to evaporate and
not participate in the setting up process. In addition to acting as a solvent, the
styrene participates in the polymerization process. In order for this material to
begin to react, a catalyst must be added to initiate the reaction.
Additives Driers -are added to assist in the curing process.
Reflective Beads Beads -are uniformly applied across the entire width
of the marking by either a gravity or pressurized bead applicator located
immediately behind the polyester spray gun. Beads are generally applied at a
rate of 8 lb/gal
 Unsaturated polyester resins are further classified into the
following categories:
•Ortho-phthalic polyesters –resins made from ortho-
phthalic anhydride are generally cheaper than the other two
classes of unsaturated polyester resins. They are usually
used to manufacture general purpose composite laminates
where only moderate structural properties are required.
•Iso-phthalic polyesters –resins made from Iso-phthalic acid.
These resins are much more structurally competent than the
ortho-phthalic resins. They also have superior corrosion
resistance and are used for more demanding applications
•Tere-phthalic polyesters –Tere-phthalate resins are made
from tere-phthal icacid. These resins are currently made in
small volumes and are considered a specialty resin.
Although they tend to have better
Silicones, also known as polysiloxanes, are
polymers that include any inert, synthetic
compound made up of repeating units of
siloxane, which is a chain of alternating
silicon atoms and oxygen atoms, frequently
combined with carbon and/or hydrogen.
They are typically heat-resistant and rubber-
like, and are used in sealants, adhesives,
lubricants, medicine, cooking utensils, and
thermal and electrical insulation. Some
common forms include silicone oil, silicone
grease, silicone rubber, silicone resin, and
silicone caulk.
 PROPERTIES
Long bond length combined with a wide bond angle and a low
barrier to rotation give polydimethylsiloxane(PDMS) outstanding
flexibility, internal mobility, and large free volume.

Resists temperature extremes, weathering, aging, oxidation,

moisture, many chemicals, and ultraviolet radiation.
Is generally non-irritating.
Silicones are highly permeable to oxygen, nitrogen, and water
vapor (but not to water molecules).
Silicones have a very springy nature.
You can compress them, stretch them, bend them, smash them,
and spread them (over and over again),
 One way on reinforcing
plastic is to add fibred glass to it.
this makes it much stronger and is
generally referred to as G.R.P (glass
reinforced plastic)
It is used in car body
repairs, sailing boats, corrugated
sheet because of its lightness
toughness and resistance to water.
 Fibreglass is an excellent example of a relatively modern
composite material (Invented in 1938 by Russel Games). In
industry it is often referred to as Glass Reinforced Plastic
(GRP).

GRP is composed of strands of glass. Each individual glass

fibre is very fine with a small diameter, and they are woven
to form a flexible fabric. The fabric is normally placed in a
mould, for instance a mould for a canoe and polyester resin
is added, followed by a catalyst (to speed up the reaction).
The process is repeated so that there are many layers of
fibre glass and resin and allowed to dry/cure. The resulting
material is strong and light. Glass Reinforced Plastic can be
sanded for a smooth finish and painted.
Three samples of different weaves of fiberglass are seen below. The pattern
of weave determines the strength and weight of the Glass Reinforced
Plastic, after resin has been added. Different weaves have been developed
for different practical applications.
Glass reinforced plastic is lightweight and has good thermal insulation properties. It
has a high strength to weight ratio, making it useful for the production of products
such as water tanks, surfboards, canoes, small boat hulls and similar products. The
new European fighter plane, called ‘Eurofighter’, has an airframe which includes 12%
glass reinforced plastic.
 ADVANTAGES
1. Non-Conductive Properties.
One of the main reasons for using GRP is the fact that it does
not conduct electricity. This is a key benefit in order to provide a
safe working environment especially when working in
environments where there are electrical risks such as around
railways.
2 Resistant to Corrosion
A key reason for using GRP is their corrosion resistance. In most
cases, you will find that glass reinforced plastic is the only
material that can properly handle a particular service
environment, while in other cases, their resistance to corrosion
gets combined with its costing making GRP a solution that is
economically viable.
 3. Weight Advantages
Another very distinct advantage of glass-reinforced plastic is found in its low weight
to potency ratio. As a rule, for a similar strength, GRP will weigh half the weight of
aluminum and a seventh of steel.
Its lightweight properties are a key selling point, particularly when you consider the
simplicity and the cost of installation, especially when it comes to tanks and pipes.
GRP’s inherent light weight is advantageous when it comes to mounting equipment
on existing structures.
4. High Strength
High strength plays a vital role when it comes to designing man load bearing
structures and GRP fulfills this need. The high strength properties of GRP allow for
less material to be used than other more traditional structural materials thus
lowering cost and weight.
5. Economy
One of the major advantages of glass reinforced plastic is the fact that it is very
affordable. When compared to other corrosion resistant materials such as titanium
and stainless steel GRP will often provide a more economic solution allowing
construction companies to complete jobs on budget
Therefore glass reinforced plastic will act as a satisfactory solution to the corrosion
problems and come at a very affordable cost.
 DISADVANTAGES
Composite materials tend to be more brittle when compared to
wrought metals, and thus are very easily damaged. Cast metals
are also very brittle.
When repairing glass-reinforced plastics, you introduce new
problems to the equation. Such as
• The materials often require a transport vehicle that is
refrigerated and will often have a very limited shelf life.
• In many cases, hot curing is required, and thus requires the use
of specialized equipment
Another disadvantage arises when rivets have been used, and
will need to be removed. Removal presents a new set of
challenges, as the rivets must be removed without causing any
further damage to the glass-reinforced plastics.
Hand Lay-up of Glass Reinforced Plastic (GRP)
The easiest method of making a GRP product, e.g. a canoe is to use a
mould. The mould may be made from GRP or it may be made from another
structurally strong material.
The mould is first checked for defects, any scratches etc. are filled.
The mould is then polished with a wax polish to a very smooth, high quality
finish. Next, a very thin film of a liquid release agent is applied to the inside of
the mould. The wax and the release agent are there to prevent the glass fibre
product from sticking to the mould.
The gel coat is the first layer of resin to be applied to the mould. The
gel coat is a mixture of polymer resin, hardener and a pigment mixed in the
proportions recommended by the resin manufacturer. An exothermic reaction
occurs as the hardener reacts with the resin and heat from the reaction causes
the resin to cure and harden.
 When the gel coat has cured, a layer of fibre reinforcing
material such as strand glass fibre is laid inside the mould and a
measured amount of polyester resin mixed with a hardener is
stippled and rolled into the reinforcing layer. Once again an
exothermic reaction occurs causing the resin to cure and harden and
bond with the gel coat layer. When the first GRP/FRP layer has
cured, another layer of fibre reinforcing material is laid in the mould
and resin is stippled and rolled into it. As each layer cures, more
layers may be applied until the required thickness is achieved.
When the product has fully cured, it may be removed from
the mould. The coloured gel coat that was on the inside of the
mould is now the exterior covering of the GRP product.
Any blemishes in the mould will have been reproduced in
the finished moulding.
Thermoset Plastic Manufacturing Process
Thermoset plastic industrial laminates are identified
in process by three stages: A, B and C.
•A-stage -refers to the key raw materials described
earlier -reinforcing substrates and resin binders.
•B-stage -refers to the product produced when
reinforcing substrates and resin binders are brought
together but not fully cured. The reinforcing
substrate is unwound from a large master roll and
dipped into a bath of liquefied resin binder.
•C-stage-refers to sheet, rod, tube, angle or other in
their "cured stage“.