TOOLING MATERIALSApplication / Aerospace tooling
The master model establishes the geometry and finish that a carbon-fibre mould will reproduce. Its construction must remain stable through the mould lay-up, initial cure and release process. EPTEK supports four distinct manufacturing methods.
Engineering requirements
01 / FOAM-BASED BUILD
Shape the foam substrate, laminate the glass-fibre skin, then apply the epoxy tooling paste. CNC machine the cured working layer and finish with the specified gelcoat. The skin distributes local loads; the paste provides the machining allowance.
02 / CAST BLANK
Prepare the casting cavity and pour the selected filled tooling system under its prescribed thickness and cure conditions. Demould the cured blank, machine it to CAD geometry and finish the surface. Control heat build-up, voids and shrinkage during casting.
03 / FRAME-BASED BUILD
Build the support frame, form and seal the glass-fibre skin, then apply and machine the tooling paste. Finish the working surface with a compatible gelcoat. Frame restraint, skin support and thermal movement must be considered together.
04 / BONDED BLOCK
Cut and bond the selected boards into a blank with a compatible adhesive. Allow the bondlines to cure before referencing and CNC machining. Check seams, surface finish and the stability of both board and adhesive through the subsequent mould-making cycle.
Engineering requirements
| Construction | EPTEK materials | Key decision |
|---|---|---|
| Foam-supported master | PUFOAM + EPLAM laminating systems + EPMOLD tooling pastes + gelcoat | Foam support, skin integrity, paste thickness and compatible cure |
| Filled casting | PUCAST or EPCAST systems | Casting volume, filler package, exotherm, cure and machining allowance |
| Steel-frame master | EPLAM + EPMOLD + gelcoat | Frame design, local support and surface-layer continuity |
| Board master | PUBOARD model boards or EPBOARD epoxy tooling boards, with matched adhesive | Temperature during mould manufacture, size, seams and required finish |
Engineering requirements
Start with the dimensional tolerance, model size, surface finish and the actual initial cure cycle of the carbon-fibre mould. Confirm the board or resin, joints, coating and support structure together. The eventual service temperature of the finished composite mould does not by itself define the master material.