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polymer mineral casting process

Cleveland Polymer Technologies (CPT) manufactures precision polymer castings

process of making Polymer concrete

polymer castings - Process

CPT uses a proven system under the trademark POLY-CRETE™, a non metallic polymer mineral composite material. The process is outlined below.

Design, Mold and Production

Part Design:

CPT will assist in the design of the mineral casting to ensure maximum utilization of the technology and the material. CPT will also provide system solutions by incorporating various components into the casting to minimize assembly at the customer's site. We work together with motion control and linear guide manufacturers to offer a complete solution to the customer. CPT will offer the customer the best advice possible to ensure a rigid design and economies of scale including alternative methods of production such as post grinding, replication and grouting.

Molds:

The mineral casting process requires the build of a mold. Molds are built from different materials like wood, fiberglass, fabricated steel, aluminum and steel. The choice of the mold material depends on required part accuracy, unit production and life cycle of the product.CPT will assist in the design of the mineral casting to ensure maximum utilization of the technology and the material. CPT will also provide system solutions by incorporating various components into the casting to minimize assembly at the customer's site. We work together with motion control and linear guide manufacturers to offer a complete solution to the customer. CPT will offer the customer the best advice possible to ensure a rigid design and economies of scale including alternative methods of production such as post grinding, replication and grouting.

Wood molds are used for prototypes and some times for limited production parts (special machines). They are quick to manufacture, inexpensive, but do not produce finish accuracies. Fabricated steel molds are utilized when production runs are small, usually less than 100 castings and high accuracy is not required. These molds are considered medium level in both cost and quality. Fiberglass molds are ideal when intricate and round shapes are required. Like fabricated steel these molds do not produce high cast accuracies and volume is typically less than 100 parts. Fiberglass molds are also considered medium level in cost and quality. Steel molds are the preferred production molds. They are made from thick steel plates (3/4" - 1") and can maintain a high level of accuracy. Steel production molds can last hundreds of parts. They are the most expensive and it takes longer to manufacture.

Grouting:

This is an alternative method to scraping and shimming. A machine column can be easily mounted and aligned onto the base by grouting. Grouts are epoxy resin compounds specifically formulated for that purpose.

Replication:

Epoxy based resin systems are used to replicate surfaces onto the castings by the use of a master fixture. This is an alternative method to grinding which can be costly and time consuming.

Production:

The castings are produced in room temperature. The mold is placed on a vibrating table to ensure proper compaction of the material and to minimize voids. Vibrating frequencies vary depending on the construction material of the mold and the mass of the casting.