Chopping & Lamination
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Chopper & Lamination Solutions for Open Mold Composite Fabrication
Kirkco understands the importance of precision when processing multi-component materials. Different systems are required for different materials. There are three mixing systems available to process variances in viscosity, mixture properties, short pot life, etc.
Hand Lay‑Up: Fundamental Open Mold Method
Hand lay‑up is one of the most basic and widely used open mold processes. It involves manually placing reinforcement materials such as fiberglass mats or woven fabrics into a mold, followed by application of catalyzed resin using brushes, rollers, or similar tools. Rollers or squeegees are used to thoroughly wet out the reinforcement, eliminate air entrapment, and consolidate the laminate layers. Multiple layers are added until the desired thickness is attained, often incorporating core materials for stiffness or tailored performance.
Benefits of Hand Lay‑Up:
- Minimal equipment and low tooling cost
- Flexibility in part size and shape
- Good for low‑volume production and custom components
- Easy design changes during build-up
Spray Lay‑Up: Efficient Fiber & Resin Application
Spray lay‑up builds on hand lay‑up by using a chopper gun to simultaneously dispense chopped reinforcement fibers (e.g., fiberglass) and catalyzed resin onto the mold surface. The chopped fibers are cut to controlled lengths and entrained in the resin stream, allowing rapid build‑up of laminate thickness. After spraying, rollers compact the laminate to ensure uniformity, reduce voids, and promote adhesion between layers.
Key Advantages of Spray Lay‑Up:
Faster laminate buildup than hand methods
Adjustable spray parameters for resin flow and fiber distribution
Suitable for larger or complex parts
Can be adapted to manual or automated production for throughput gains
Chopper Lamination Fundamentals
Chopper lamination refers broadly to the combination of chopped fiber reinforcement and resin application in open mold settings. In this process, continuous strands of reinforcement feed through a chopper unit to create controlled fiber lengths that are combined with catalyzed resin and applied to the mold. This method enables tailored fiber content, rapid layer buildup, and scalable production environments.
Applications Across Industries
Chopper and lamination processes are used in the production of large or complex composite components where cost‑effectiveness and flexibility are critical. Typical applications include:
- Marine hulls and decks
- Storage tanks and containers
- Recreational vehicle components
- Structural and architectural parts
- Industrial panels and housings