The fiberglass shell customization process usually includes demand confirmation, design, mold making, production, post-processing and acceptance. The following are the detailed steps:
1. Demand confirmation
Clear use: determine the application scenarios of the shell (such as equipment protection, ships, automobiles, buildings, etc.) and functional requirements (waterproof, anti-corrosion, high temperature resistance, etc.).
Technical parameters: determine the requirements of size, shape, thickness, color, strength, weight, etc.
Environmental conditions: consider factors such as temperature, humidity, corrosiveness, and UV exposure in the use environment.
2. Design stage
3D modeling: perform structural design according to requirements and use CAD/SolidWorks and other software to make three-dimensional models.
Material selection: select resin type (such as epoxy, unsaturated polyester) and reinforcing materials (such as glass fiber felt, cloth).
Process design: determine the molding process (hand lay-up, injection, molding, vacuum introduction, etc.).
Feasibility assessment: check whether the design meets the strength, cost, and production feasibility requirements.
3. Mold making
Prototype verification: If high precision is required, a 3D printed or CNC machined prototype may be made first.
Mold development: Make molds (wooden molds, fiberglass molds or metal molds) according to the design to ensure surface finish and dimensional accuracy.
Mold treatment: Spray mold release agent to facilitate subsequent demolding.
4. Manufacturing
Material preparation: Cut fiberglass cloth, mix resin (add curing agent, pigment, etc.).
Molding process:
Hand lay-up molding: Manually lay fiber cloth, brush resin, and stack layer by layer.
Spray molding: Spray resin and chopped fibers onto the mold with a spray gun.
Molding/VRTM: Suitable for mass production with higher precision.
Curing: Curing at room temperature or heating to ensure complete hardening.
5. Post-processing
Demolding: Carefully remove the cured shell to avoid damage.
Finishing: Cut burrs, drill holes, and grind the surface.
Surface treatment: Spray paint, polish or apply UV protection coating.
Quality inspection: Check size, strength, and appearance defects (such as bubbles and cracks).
6. Acceptance and delivery
Performance test: Load, waterproof, corrosion resistance and other tests are carried out according to requirements.
Customer confirmation: Provide samples or photos for confirmation, and adjust details (if necessary).
Packaging and transportation: Shockproof packaging to avoid transportation damage.
Key points
Cost control: Mold costs are high, and hand lay-up may be more recommended for small batch production.
Construction period: Mold making takes 30%-50% of the time, and more cycles are required for complex designs.
Environmental requirements: Resin treatment must meet environmental protection standards, especially for export products.
Applicable industry cases
Industry: fan cover, cable tray.
Transportation: car bumper, hull.
Architecture: antique decoration, roof dome.
Through the above process, it can be ensured that the FRP shell customization meets the expected performance and appearance requirements. It is recommended to cooperate with experienced FRP manufacturers, especially to optimize the solution in the design and mold stages.
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