Mold-making: Vinyl Ester, Fiberglass layup

Table of contents

Teams that do this

Baja, FSAE, Hyperloop, CEV

Chemicals involved & MSDS for each (should also be included in confluence SDS) 

Safety Gear

• Long sleeve shirt
• Work gloves (for extra protection can wear nitrile gloves under the work gloves)
• Gray masks/respirator

Step by step

The second step in the mold-making process is to apply fiberglass to the sprayed gelcoat surface. The fiberglass is stuck on with resin, and once the resin cures, the orange fiberglass mold can be “popped-off” the plug.

1. While waiting for the gelcoat to cure, you can start ripping/cutting pieces of fiberglass chop strand. The fiberglass pieces will be placed on top of the gel coat. 
2. Using brushes, dab an even coat of vinyl ester across the gelcoatted plug. Apply the first layer of fiberglass. In places where there are sharp bends, be sure to apply small pieces of fiberglass veil (thin fabric material) as the first layer. These can fit into small cracks more easily and ensure the mold will fit accurately to the plug.
3. After the fiberglass is placed, dab more vinyl ester liberally on top, pressing out air bubbles within the chop strand. Apply 3-6 layers of fiberglass chop strand (thicker, mat-like material) on top of the mold, depending on the desired stiffness/thickness of the mold.