Forming A Laminate Resin Sheet

Overview

Lamination is a process where layers are continually added to each other until reaching a desired strength or thickness. Laminate resin sheets are used in the fiberglass fabrication of anything from boats to industrial air scrubbers. Creating a resin laminate sheet requires some detailed preparation, but minimal experience or skills are needed.

Things You'll Need

  • Fiberglass mat
  • Resin solution
  • Hydrogen peroxide catalyst
  • 9 inch felt roller
  • 6 inch air roller
  • Sheet of mylar
  • Spray glue
  • Window squeegie
  • Bucket
  • Stir stick
  • Metal paint scraper
  • Table
  • Razor knife
  • Clear packing tape

Step 1

Determine the size and thickness of the sheet that is needed, and using your razor knife, cut the fiberglass mat accordingly. If using the standard 1.5 ounce mat, 7 layers will be 1/4 inch thick. Cut the mat 2 inches longer than needed on all four sides to leave room for error. Set aside.

Step 2

Wipe the face of the table with a damp rag to assure its clear of dust and then evenly coat the table with spray glue. Lay the mylar down covering the entire face of the table.

Step 3

Use the squeegee to get all of the air bubbles out from underneath the mylar. Any bubbles or creases in the mylar will show up on the bottom of your finished sheet.

Step 4

Fill your bucket with 19 parts resin and add 1 part catalyst. The amount of each that you will use depends on the size of your sheet. Pour the catalyst into the resin solution. The ratio for resin to hydrogen peroxide is 19 parts resin to 1 part catalyst. Stir your mixture for 45 seconds to 1 minute, or until it is thoroughly mixed.

Step 5

Use your felt roller to wet the top of the table with the resin mixture. Put the first layer of mat down in the center of the table and saturate the mat evenly with the resin mixture.

Step 6

Using the air roller roll all the air bubbles out of the layer of mat. Continue the same process for each layer until all of your pre-cut pieces are applied.

Step 7

Let the sheet cure for 1 hour. If the sheet is hard and cool to the touch, use your metal paint scraper to gradually pry the edges all the way around the sheet until it loosens and releases from the mylar.

Warnings

  • Catalyst is a chemical that can create chemical burns when skin is exposed to it.
  • Always wear a mask when using fiberglass, to prevent strands of glass from entering the lungs.
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