Sika a Global Network

Sika Tooling & Composites Sika Industry Sika Deutschland GmbH Stuttgarter Str. 139 D-72574 Bad Urach Germany Tel: +49(0) 7125 940 492 Fax: +49(0) 7125 940 401 e-mail: tooling@de.sika.com
Subject to alterations in the course of technical progress and also subject to error. 03.09

Actual Technical Data Sheets and informations about additional products please find in: www.sika-tooling.com www.sika.de

28

SikaBlock and Biresin Ideas take Shape

Block materials and Model pastes Vacuum Casting resins and RIM-systems Composite and Laminating systems EP- and PUR-Casting resins Elastomeric casting resins Auxiliary materials

Ideas take Shape

In the almost 100 years since the company was established by Kaspar Winkler in 1910, Sika has developed into a globally operating company for specialist chemicals. More than 12,000 employees all round the world work with our customers to create innovative products and solutions in the areas of construction chemicals and industry. Sika achieves a turnover of CHF 4.5 Billions per year.

As an integral part of this strong association but nevertheless operating independently, the company's Tooling & Composites division develops and produces customized products for pattern and mould construction, foundry systems, rapid production and composite production. All the core functions such as research and development, production, marketing/sales, and technical service, are gathered together at one location in Bad Urach at the foot of the Schwbische Alb. Customer requirements can thus be met quickly and efficiently and this is backed up by the possibility of exploiting the know-how of over 600 developers world-wide.

Our customers and their satisfaction are the focal point of our activities. For you, this means: Expert on-site consulting provided by our staff Training and technical support by a service team composed of experienced model makers and technicians A complete range of PUR- and EP-systems for the area of Tooling & Composites. World-wide availability of materials through a network of competent trading partners

SikaBlock and Biresin Our Product Groups

Block materials and Model pastes The suitable system for any application. n Model and Tooling boards n Suitable Adhesive and Filler systems n Model and mould making pastes A wide range of application-oriented system solutions consisting of special SikaBlock board materials and the associated Biresin Adhesives and Fillers can be used for many applications in the construction of master-, design, styling and cubing models as well as for diverse moulds, foundry patterns and other manufacturing tools. Biresin Model pastes are tailor-made products for making joint-free design, styling and cubing models and diverse moulds in high quality.

Vacuum Casting resins and RIM-systems Complicated mouldings quickly made. n Vacuum Casting systems n Low pressure RIM-systems For classic rapid prototyping our Biresin Vacuum Casting systems based on polyurethane are suitable. They are simulating the majority of characteristics of the thermoplastic series materials. The same applies for the product group of the Biresin Low pressure RIMsystems, which are processed with the help of 2-component-mixing and metering machines. Because of very short demoulding times the LP-RIM-casting is suitable above all for serial production.

Composite and laminating systems Together they are strong. n High Performance Composite systems n Gelcoats n Laminating and Multipurpose resins Biresin Composite resins are specially designed for the production of high performance composites also giving good wetting of difficult carbon fibres, variable viscosity for different production processes and application temperature ranges from 80 to 170C. Excellent processing and good resistance to external influences are the deciding features of Biresin gelcoats. The Biresin Laminating systems can be used in different stages of manufacture in the construction of models, negatives, moulds and tools.

P. 6/7

Model and Tooling boards

P. 8/9

Model and mould making pastes

P. 10/11

Vacuum Casting systems

P. 12/13

Low pressure RIM-systems

P. 14/15

High Performance Composite systems

P. 16/17

Gelcoats Laminating and Multipurpose resins

EP- and PUR-Casting systems Everything made in one casting. n n n n Fastcast resins EP-Casting resins Heat-resistant Casting resins PUR- and Backfill-Casting systems

Elastomeric Casting resins Flexible also with regard to possible applications. n Elastomeric Casting resins for mould making n Elastomeric Casting resins for foundry pattern making The range of elastomeric Biresin PUR-Casting resins includes highquality synthetic resin systems with a variety of shore hardness levels (Shore A40 D70) and possible applications. The soft elastic types are used for making flexible moulds and mouldings. The tough elastic and tough hard types are suitable for shock resistant parts and abrasion resistant liners in foundry pattern making and special mechanical engineering. P. 18/19 Fastcast resins

P. 20/21

The large range of Biresin Tooling resins can be used in many different ways. They are suitable for the quick and inexpensive manufacture of production equipment such as foam-, RIM- and vacuumforming moulds or foundry patterns and metal sheet forming tools. There are also suitable casting resins for making auxiliary items such as master and core models or negatives. The system selected depends on the casting procedure in question, e.g. mass casting, backfill or facecasting.

EP-Casting resins Heat-resistant Casting resins PUR- and Backfill-Casting systems

P. 22/23

Elastomeric Casting resins for mould making and foundry pattern making

P. 24/25

Adhesives Fillers

P. 26/27

Surface pre-treatment Filling materials, Auxiliary materials

SikaBlock Model and Tooling boards

Whether design or data control model, whether gauge or core box SikaBlock board materials are the optimum products for all applications. There are 13 different board types with densities of 0.08 to 1.2 kg/dm2. They are available in different dimensions and thicknesses of up to 2000 x 1000 x 600 mm. In accordance with requirements, the materials also differ in respect of their structure, as well as their mechanical and thermal characteristics. Numerous quality checks help to monitor compliance with these standards. For us, certification to DIN EN ISO 9001 is a natural expression of our attitude towards quality.

When it comes to development and product updates, we place special value on the following characteristics: n Physiological harmlessness n Easy to work material with little wear on tools n Low levels of dust and smell n Very small tension levels and therefore low deformation n Low coefficient of thermal expansion and therefore dimensionally stable n Homogeneous structure and dense surface quality n Sufficient strength and heat resistance

SikaBlock Model boards

SikaBlock
Density [g/cm] Colour Characteristics M80 0.08 beige M150 0.15 beige M300 0.3 light orange easily workable, fine structure and homogeneous surface design and styling models, substructure for cubing and DCM, test milling M450 0.45 orange easily workable, homogeneous surface, low dust formation design and styling models, substructure for cubing and DCM ; ; ; ; ; 37.5 56.25 75 112.5 150 M650 M700 0.58 0.7 reddish brown light brown easily workable, dense fine surface, good compressive strength and edge stability, high heat distortion temperature, good solvent resistance, low coefficient of thermal expansion master models, cubings, DCM, moulds and tools for lower number of pieces (low pressure RIM, vacuum forming, etc.) 1500 x 500 x 25 37.5 1500 x 500 x 50 56.25 1500 x 500 x 75 75 1500 x 500 x 100 112.5 1500 x 500 x 150 Kleber braun 100 : 65 20 min 8-10 h Spachtel braun 100 : 2 5 min > 20 min ; ; ; ; ; ; ; ; ; 18.75 37.5 56.25 75 112.5

easily workable, fine, homogeneous surface, high heat resistance styling models, design studies and test milling, substructure for design, styling and clay models

Applications

Processing data (approx.-values)

Dimensions mm]; [ltr.] 2000 x 1000 x 100 ; 200 2000 x 1000 x 200 ; 400 blocks up to 600 mm thickness on request Foam Adhesive 1-component, humidity curing open time: 10 min 6-8 h Spachtel orange 100 : 2 5 min > 20 min D6 D 14 1.2 2.8 application temperature -80 up to +130C 70 x 10-6 60 x 10-6 1500 x 500 x 50 1500 x 500 x 50 ; 37.5 1500 x 500 x 75 1500 x 500 x 100 ; 75 1500 x 500 x 100 1500 x 500 x 200 ; 150 1500 x 500 x 150 1500 x 500 x 200 Kleber orange 100 : 65 20 min 6h Spachtel orange 100 : 2 5 min > 20 min D 30 5 78 60 x 10-6 D 50 12 78 55 x 10-6 1500 x 500 x 50 1500 x 500 x 75 1500 x 500 x 100 1500 x 500 x 150

Adhesive

Filler

Biresin Mixing ratio Potlife Setting time Biresin Mixing ratio Potlife Setting time

Physical data (approx.-values)

Shore-hardness Flexural strength [MPa] HDT [C] CTE, T [1/K] D 58 18 85 50-55 x 10-6 D 66 26 90 50-55 x 10-6

SikaBlock Tooling boards

SikaBlock
Density [g/cm] Colour Characteristics M911 1.1 ivory M940 M960 M970 1.2 turquoise very abrasion resistant, excellent milling properties, very high strength M1000 1.0 white low density, high dimensional stability gauges, moulds, foundry and master models 1500 x 500 x 50 ; 37.5 1500 x 500 x 75 ; 56.25 1500 x 500 x 100 ; 75 M1050 1.0 grey M2010 0.73 light green high heat distortion temperature, low coefficient of thermal expansion, high compressive strength vacuumforming moulds, prepreg and laminating moulds 1.2 1.2 green blue very abrasion resistant, very abrasion resistant, extremely high abrasiexcellent milling excellent milling on resistance, free from properties, best properties, softeners price/performance ratio impact resistant foundry models, core boxes for seriese

Applications

foundry patterns and core boxes, metal sheet forming tools, mouldings and master models

Processing data
Dimensions [mm]; [ltr.] dimensions on request U1320/U1303 100 : 38 10 min approx. 6 h Schnell Kleber blau 100 : 60 3 min 1h D 80 90 85 85 x 10-6 D 78 80 80 85 x 10-6 D 84 110 78 68 x 10-6 1000 x 500 x 50 ; 25 1000 x 500 x 75 ; 37.5 1000 x 500 x 100 ; 50 Power Adhesive Thix 100 : 33 30 min 16 h Spachtel wei 100 : 2 5 min > 20 min D 75 48 85 50-55 x 10-6 recommendation: Polyesterspachtel Supermetall (Hohnen & Co.) D 76 50 90 50-55 x 10-6 1524 x 610 x 50 ; 46.5 1524 x 610 x 100 ; 93.0 HT Adhesive 100 : 15 30-35 min approx. 16 h -

Adhesive

Filler

Biresin Mixing ratio Potlife Setting time Biresin Mixing ratio Potlife Setting time

Physical data (approx.-values)

Shore-hardness Flexural strength [MPa] HDT [C] CTE, T [1/K] D 62 18 120 155 x 10-6 D76 40 > 210 35-40 x 10-6

Biresin Model and mould making pastes

The manufacture of high-quality, completely joint-free design, styling and cubing models as well as moulds is the domain of Biresin Model pastes. They are mainly processed on 2-component mixing and metering machines. The cured resin systems are easy to finish to their correct dimensions by mechanical means. The results are joint-free, smooth surfaces with a high level of precision which can then be covered with layers of paint.

Biresin Model and mould making pastes

Biresin
Mixing ratio Colour Characteristics [g] A B A B 30 M60 M60 S10 100 15 12,5 brown EP paste, high edge stability, easily workable, low shrinkage F4 M72 M70 100 45 brown PUR paste, easily workable, fine, dense surface, easy to varnish M72 Classic M73 M70 100 56 brown PUR paste, easy workable, fine dense surface, high thermal resistance, for heat resistant substructures M75 M70 100 48 grey PUR paste, high thermal resistance, easy workable, very fine and dense surface machine paste coating on substructure for the production of models and laminating moulds 15,000 175 pasty 15 >8 M82 M82 100 100 brown EP paste, easily workable, fine, dense surface, easy to varnish machine paste coating on substructure for the production of design, styling and cubing models 70,000 150,000 pasty 20 - 30 > 24

Applications

hand applicable paste with hardener M60, with F4 also castable, with S10 as adhesive A B pasty 4,000 pasty 15 > 12

machine paste coating on substructure for the production of design, styling and cubing models

Processing data (approx.-values)

Viscosity Mixture Potlife Workable after Filler [mPas] 15,000 < 10 castable 20 > 16 175 pasty 10 - 15 (after coating) >8 >8 Spachtel braun 100 : 2 5 min > 20 min 0.9 D 70 32 65 9,000 pasty pasty 30 > 16 18,000 175 pasty

[min] [h] Biresin Mixing ratio Potlife Setting time [g/cm] [MPa] [C]

Physical Data (approx.-values)

Density Shore-hardness Flexural strength Tg value 0.77 D 65 25 0.7 D 69 32 0.75 D 67 28 0.9 D 65 20 47 1.3 D 79 61 70 0.78 D 59 19 52 / 65*

* after appropriate thermal treatment (refer to Technical Data Sheet)

Biresin M72 the fastest model paste in the market n Low inherent stress allows application to largest areas n Good adhesion on EPS without previous laminate layer n Milling possible after 8 hours n Very low dust when milling n Attractive price

Biresin M73 high heat distortion temperature, e.g. for wind power blades n Tg value 65C without postcuring n Heat resistance even without postcuring on the equivalent to postcured epoxy pastes this saves time and money n Excellent milling behaviour: very fine and dense surface n Requires heat resistant substructures

Biresin M75 the mould making paste n Very fine and dense surface n Very good resistance against chemical attack (such as polyester) n In practice more than 80 C heat resistance n No postcuring of the mould required

Biresin M82 the paste for large scale models n Very fine and dense surface n Interruptions of working process possible at every time n No postcuring of the mould required n Postcuring increases temperature resistance

Biresin Vacuum Casting systems

Application: n Fast and cost-effective production of high-quality prototypes and short run parts n Simulation of materials as used in serial production (like rubber, soft-PVC, polyethylene, polypropylene, ABS, PVC and others) in stage of development and preproduction for automotive industry, consumer goods and other technical parts n Processing by easy hand casting or by means of vacuum casting equipment

Range of application: n Modular assembly system with universal hardeners offers a wide range of E-moduli and further characteristics n Biresin VG70 and Biresin U1419: Flexible systems with good elongation characteristics n The fast setting fastcast resins with special hardeners present high-quality materials with an excellent price-performance ratio in this E-modulus area of PE, PP and ABS n Biresin VG185 HT in use for impact resistant ABS-housings of high heat resistance n Biresin VG230 and Biresin VG280 excel by higher stiffness and strength at simultaneously high impact resistance. Adding of Biresin G48 resin extends the potlife

Biresin Vacuum Casting systems

Biresin Mixing ratio Colour Characteristics A B A [g] B VG 70 G53 100 18 black flexible, simulates rubber, soft-PVC sealing, bellows etc. [mPas] [sec] [min] [g/cm3] [MPa] [N/mm] [MPa] [%] [kJ/m] [C] 900 6 45-60* 1.1 A 70 9 200 U1419 U1419 100 16 yellowish-transparent high tear strength, high rebound elasticity, simulates PE, PP tough-hard mouldings

Applications

Processing data (approx.-values)

Mixed viscosity Potlife Demoulding time Density Shore-hardness E-Modulus Tear strength Flexural strength Elongation at break Impact strength HDT 2,700 6-7 > 60* 1.1 A 100 (D 54) 68 375 -

Physical data (approx.-values)

10

Biresin Vacuum Casting systems

G27 LR G27 wei 100 100 100 beige white impact resistant, simulates PE, PP thinwalled parts with complex structure G27 G53

G 26 U5 100 75 beige heat resistant, simulates PE, PP thinwalled parts of good heat resistance 67 U5

G 28 G53

VG185 HT

VG230

VG240

VG280

G56 G55 G55 G55 100 80 90 57 80 67 75 100 100 100 100 beige black yellowish-translucent yellowish-translucent yellowish-translucent very stiff, high flexural heat resistant, impact resistant, high stiff, very impact stiff, very impact strength, impact resist., simulates heat distortion temperaresistant, resistant and high simulates ABS, PVC PE, PP, ABS ture, simulates ABS simulates ABS flexural strength impact and high heat very stiff housings very impact resistant thinwalled parts of resistant housings, very impact and covers of high housings, covers and good heat resistance thinwalled parts with resistant housings strength and impact other mouldings complex structure resistance 120 4 60-90 1.1 150 5 60-90 1,500 6-7 > 45* 1.2 D 83 1,850 _ 95 50 120* 900 4 60* 1.1 D 82 2,300 90 > 100 70 950 8 60* 1.2 D 83 2,400 115 > 100 90* 600 4 60-90* 1.1 D 84 2,800 120 > 100 80

50 4-5 60-90 1.1 D 70 730 40 40 75

30 4-5 60-90

120 2 > 20 1.1

110 140 > 20

D 70 925 40 70 70

D 75 1,310 65 30 95*

D 77 1,510 71 25 105*

D 79 1,500 67 25 102*

D 79 1,610 72 25 95*

* after appropriate thermal treatment (refer to Technical Data Sheet)

11

Biresin Low pressure RIM-systems

Application: n Curing PUR resins for use on 2-component mixing and metering machines for the manufacture of individual parts or series manufacture of several thousand pieces n Simulation of materials of serial production (like rubber, polyethylene, polypropylene, ABS, PVC, and others) in stage of development and preproduction for automotive industry, for household appliances, for rail vehicles, in aviation, in boat building and for other technical parts n For small parts (< 0.1 ltr.) to big volume parts (appr. 20 ltr.)

Range of application: n Unit assembly system with only two general-purpose hardeners: Biresin U5 hardener for higher temperature resistance Biresin G53 hardener for higher mechanical properties n Natural (colourable) and coloured resins n Biresin RG51 Fibre and Biresin RG53 Fibre as fibre filled products with very high impact resistance and stiffness for special applications, e. g. in automotive industry

Biresin Low pressure RIM-systems

Biresin Mixing ratio A B A [g] B [ltr.] B RG50 G53 100 18 15 black very flexible, simulates rubber, soft-PVC sealing, bellows etc. [mPas] [sec] [min] [g/cm3] [MPa] [MPa] 1,200 100 15 1.1 A 70 RG52 EL U5 100 60 RG51 HS RG53 EL RG51 Fibre G53 100 40 U5 100 RG53 G53 G53 U5 100 100 50 70 43 black black / beige black high impact resistant, high impact resistant, very impact resistant, abrasion resistant, wear resistant, thermal resistant, simulates PE, PP simulates PE, PP simulates PE, PP shock-resistant shock-resistant parts housings and covers housings and such as bumpers of medium stiffness covers 1,750 55 4-6** 1.15 D 67 380 17 no break 25 75 / 90* 1,300 60 > 10 1.15 D 65 450 20 no break 75 62 2,000 60 5 - 10 1.2 D 77 1,100 45 80 66 / 100*

Colour Characteristics

75 80 62 66 black black / beige very impact resistant, very impact resistant, thermal resistant, thermal resistant, simulates PE, PP simulates PE, PP stiff housings and covers 2,600 45-50 > 10 1.25 D 75 1,250 45 90 15 105** housings and covers of medium stiffness 2,200 60 > 10 1.2 D 78 1,300 54 95 120* D 80 1,400 58 90 110*

Applications

Processing data (approx.-values)

Viscosity (Resin) Potlife Demoulding time Density Shore hardness E-Modulus Flexural strength

Physical data (approx.-values)

Impact strength [kJ/m] Notched bar impact strength [kJ/m] HDT [C]

12

* after appropriate thermal treatment (refer to Technical Data Sheet) ** at 60C tool temperature

Biresin Low Pressure RIM-Systems

4000 3500 3000 2500 2000 1500 1000 500 0

10 100

E-modulus Flexural strength

67 54 45 45 1250 1300 1400 58 1650

100 90 80 70 60 50 40 30 20 10 0
RG53 / U5 RG53 / G53 RG56 / U5 RG53 RG53 FR Fibre / U5 / U5

Rubber PE / PP
17 380 20 450

ABS
55 1730

70 2200

1100

RG50 / RG52 EL RG51 RG53 EL RG51 G53 / U5 HS / G53 / U5 Fibre / G53

RG56 U5 100 80 black stiff, high flexural and impact strength, thermal resistant, simulates ABS housings and covers with high mechanical properties 2,900 50 4 - 6** 1.18 D 82 1,650 67 60 100 / 125*

RG53 Fibre U5 100 60 58 black very impact resistant, thermal resistant, simulates ABS stiff housings and covers 6,000 50 > 10 1.2 D 81 1,730 55 48 127*

RG53 FR U5 100 54 52 black flame-resistant (UL-test) thermal resistant, simulates ABS stiff housings and covers with UL94 V-0 3,500 70 > 10 1.27 D 84 2,200 70 35 110*

13

Biresin High Performance Composite systems

Aimed at part production and mould making applications in the transport, marine, wind energy and other industries, these high performance composite resins are designed to meet the highest standards of production process efficiency and end-use performance. For infusion processes lower viscosity resins are available and for wet lay up, pultrusion and filament winding there are resins with optimized viscosity. With different hardeners the potlife can be varied. The resin/hardener systems are specially designed for the three application temperature ranges of 80-100C, 120C and 170C. Suitable gelcoats for mould making and parts production please find on pages 15/16. High performance composite resins with low viscosity for RTM and infusion
n Biresin CR80 and CR81 for temperature range up to 80C n Biresin CR120 for temperature range up to 120C n Biresin CR170 for temperature range up to 160C and

processing at elevated temperatures

n Biresin CR81 especially for processing of large parts at low

temperatures
n Biresin CR80 and CR120 (all hardeners) and Biresin CR81

(hardener BiresinCH81-6) have Germanische Lloyd Approval as laminating resin for the construction of components
n In each product series the hardeners have the same mixing ratio

so they can be blended easily for customized potlife n High mechanical properties n Good and fast wettabilty

Biresin High Performance Composite systems

Biresin Mixing ratio Characteristics Applications [g] A B A B CH80-1 CR80 CH80-2 CH80-6 100 30 CH80-10 CH80-1 CR81 CH81-6 100 30 good impregnation and fast wetting RTM and infusion CR120 CH80-10 CH120-3 CH120-6 100 30 CR170 CH170-3 100 16

Processing data (approx.-values)

Potlife, RT Mixed viscosity [min] [mPas] 45 400 80 350 190 230 330 210 45 180 260 150 500 130 130 240 180 250 90/RT resp. 12/60C 1.250 4 h / 160C 2,800 69 6.1 28 172

Physical data (approx.-values)

Postcuring conditions for mechanical values Tensile-E-Modulus [MPa] Tensile strength [MPa] Elongation at break [%] Impact resistance [kJ/m] [C] Tg 2,900 78 7.1 84 88 12 h / 80C 2,900 3,000 81 83 6.1 6.3 75 68 92 85 3,000 80 6.5 76 85 2,900 79 6.4 75 12 h / 80C 3,000 3,050 81 79 6.0 5.4 82 65 12 h / 120C 2,800 2,700 80 80 5.8 6.1 55 50 113 115

14

High performance composite resins with optimized viscosity for wet lay-up processing
n Biresin CR82 for temperature range up to 80C n Biresin CR122 for temperature range up to 120C n Biresin CR122 with good demoulding properties after room temperature

Heat cured high performance composite resin for pultrusion and filament winding
n Biresin CR141, 3C-anhydride system for temperature range

up to 140C
n High mechanical properties n Good and fast wettabilty n Adjustment of the potlife via the accelerator component

curing
n Biresin CR132 for temperature range up to 130C n Biresin CR174 for temperature range up to 170C n Biresin CR82 and CR122 (all hardeners) have Germanische Lloyd Approval

Biresin CA141

as laminating resin for the construction of components

n In each product series the hardeners have the same mixing ratio

so they can be blended easily for customized potlife n Excellent mechanical properties n Very good wettability n At elevated temperatures also suitable for injection processes

CH80-1

CR82 CR122 CH80-2 CH80-6 CH80-10 CH122-3 CH122-5 100 27 100

CR132 CH132-5 100

CR141 CH141 100 90 pultrusion, filament winding

CR174 CH174 100 40 wet lay-up and infusion 240 700-1.000 8 h / 150C 2,900 63 2.9 174

30 28 good impregnation, good non draining properties wet lay-up

50 740

80 600

220 400

330 390

150 370

190 380

150 550 12 h / 125C 2,700 88 6.2 135

> 24* 600 3 h / 140C 3,200 78 3.3 18 139

2,900 78 6.1 68 83

12 h / 80C 2,900 2,900 78 84 6.5 6.4 70 55 90 83

2,900 82 6.2 56 85

12 h / 80C 2,800 2,800 84 84 5.4 5.6 47 34 114 119

* Adjustment of potlife via accelerator

15

Biresin Gelcoats and Laminating systems

n Gelcoats Biresin Gelcoats are very easy to apply and specially formulated. In accordance with their particular application, they have the necessary resistance to external influences such as mechanical, thermal or chemical stress. In other cases, the fact that they are easy to work and colour plays an important role. The gelcoats are used in the construction of models, moulds and tools as well as in composite applications.

n Laminating and Multipurpose resins Biresin Laminating and Multipurpose resins offer very good wetting behaviour of reinforcing fibres and fillers. The results are high-grade laminates with excellent strength. Their low viscosity allows bonding of large amounts of grainy filling materials for backfill stamping. They are also used for coupling layers. Biresin Laminating pastes enable time-saving manufacture of reinforcing layers. Here, layers several centimetres thick can be built up in a single stage of work.

Biresin Gelcoats
Biresin Mixing ratio Colour Characteristics A B A [g] B P7 100 20 13 transparent good wetting, mechanical resistant white S5 S15 S10 S10 100 10 blue good spreading properties and easily workable master models, gauges, negatives 35 60 12-24 1.5 D 88 63 48 S12 S12 100 8 grey heat resistant, abrasion resistant, good solvent and styrene resistance vacuumforming moulds, foundry patterns, moulds for composite production 30 45 16-24 2.1 D 92 78 > 100*

Applications

transparent gelcoat for CFRP-mouldings

Processing data (approx.-values)

Potlife Geltime Demoulding time [min] [min] [h] [g/cm] [MPa] [C] 103 102* 20 > 30 12-24 1.15 D 85 131 92* 37 75 24

Physical data (approx.-values)

Density Shore-hardness Flexural strength HDT

16

* after appropriate thermal treatment (refer to Technical Data Sheet)

Biresin Laminating and Multipurpose resins

Biresin Mixing ratio Colour Characteristics A B A [g] B LS F4 LS S10 S12 100 12 18 22 16 yellowish-transparent all-purpose, variable potlife and viscosity ordinary laminates, coupling layers and backstampings l80 L80 L80 R S12 100 25 25 12 white filled, very high dimensional accuracy true-to-size laminates for gauges and models 2,500 45 20-24 1.3 D 87 76 49 2,000 70 16-20 L74 L74 100 17 yellowish-transparent high heat resistance after post curing injection moulds and other heat resistant moulds 780 120-150 24 + post curing 1.1 D 85 120* 150* L84 L84 S12 L84 T 100 25 20 24 yellowish-transparent all-purpose, high mechanical strength and heat resistance laminating moulds, vacuumforming moulds, heat resist. backstampings 390 40 24 1,090 590 20 60 24 24 + p. c. 1.1 D 84 130 91* L89 L89 100 14 blue fibre reinforced, high dimensional accuracy, heat resistant lam. paste for reinforcement of big negatives, models, moulds and tools pasty 60 24 1.0 D 75 40 60

Applications

Processing data (approx.-values)

Mixed viscosity Potlife Demoulding time [mPas] 830 [min] 55 [h] 12 [g/cm] [MPa] [C] 350 3,500 1,230 3,400 80 10 60 40 16 8 12 20-24

Physical data (approx.-values)

Density Shore-hardness Flexural strength HDT 1.2 D83 D 80 D 83 D 82 87 88 108 96 48 46 82* 72* D 86 72 48 D 85 78 80* D 82 76 100* D 86 131* 110*

S15 S15 100 10 green workable, good chemical resistance polyester, foam and LP-RIM-moulds, moulds for composite production 60 150 16 1.55 D 88 89 103* 83 100* 25 50 16 7 S15 R

S16 S16 100 10 blue-grey high abrasion and mechanical resistance foundry patterns, match plates

S19 S19 100 12 grey high heat resistance vacuumforming moulds, injection moulds, moulds for composite production 45-60 150-180 24 1.75 D 85 73 > 150*

20 45 16 1.8 D 87 95 96*

17

Biresin Fastcast resins

n Biresin Fastcast resins Biresin Fastcast resins offer high flowability, a quick curing and this result in quick demoulding. They are easily workable. The wide range of products is characterised by filled and unfilled systems.

n Filled Biresin Fastcast resins Filled Biresin Fastcast resins are especially suitable for making e.g. master and core models and negatives with large dimensions and are characterized by low shrinkage.

n Unfilled Biresin Fastcast resins The unfilled Biresin Fastcast resins are usually used for making detailed models and mouldings with thin walls due to their excellent flowability. They can, however, be casted for thicker layers by adding filling materials to them.

Biresin Fastcast resins - filled

Biresin Mixing ratio Colour Characteristics A B A [g] B G21 G21 100 15 light grey black easily workable, short demoulding time, very fine structure, low shrinkage master and core models, negatives and mouldings of medium size 2,100 5-6 30 1.7 D 80 75 80 G24 G24 100 100 blue G25 G24 100 100 green-beige

easily workable, good flowability, very low shrinkage master and core models, negatives and mouldings of larger dimensions

Applications

Processing data (approx.-values)

Mixed viscosity [mPas] Potlife [min] Demoulding time [min] 600 8 > 120 1.6 D 80 80 75 700 4-5 30 1.6 D 80 80 85

Physical data (approx.-values)

Density [g/cm] Shore-hardness Compr. strength [MPa] HDT [C]

18

* after appropriate thermal treatment (refer to Technical Data Sheet)

Biresin Fastcast resins - unfilled

Biresin Mixing ratio Colour Characteristics A B A [g] B G26 G26 G27 G27 G27 LV G27 G27 LR G27 w G26 100 G28 G27 G27 w G55 G26 100 100 100 100 100 100 100 80 100 beige beige white beige-grey easily workable, short demoulding time, very fine structure, high filler loading models, core models, negatives, pattern, small and medium size art and craft articles with detailed shape 80 2-3 > 25 1.1 D 70 40 20 75 D 70 45 25 80 D 70 55 25 80 50 30 140 215 215 130 > 20 > 20 > 15 1.1 D 70 40 60 75 35 220 > 15 1.1 D 70 45 23 75 G27 G27 w 100 100 100 100 100 100 beige white beige white easily workable, longer potlife, low shrinkage, good flowability, high filler loading models, core models, negatives and pattern articles with medium to large dimensions 50 4-5 > 70 1.1 D 70 40 40 75 69 70 30 4-5 > 90 80 7-8 2-3 h 90 6-7 2h 1.1 D 69 40 28 80 60 6-7 2-3 h

Applications

Processing data (approx.-values)

Mixed viscosity [mPas] Potlife [min] Demoulding time [min] Density [g/cm] Shore-hardness Flexural strength [MPa] Impact strength [kJ/m] HDT [C] 70 3-4 > 30

Physical data (approx.-values)

D 75 60 50 75 D 68 41 20 75 D 68 35 40 75

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Biresin EP- and PUR-Casting systems

The large range of Biresin Casting resins based on epoxy and polyurethane can be used in many different ways. The resin systems are highly resistant to mechanical or thermal influences. The system selected depends on the casting procedure in question, e.g. mass casting, backfill or facecasting.

n EP-Casting resins In accordance with their particular application, the Biresin EP-Casting resins have a good resistance to chemical stress and / or abrasion. Therefore they are suitable for the quick and inexpensive manufacture of production equipment such as foam-, RIM- and vacuumforming moulds as well as foundry patterns and metal sheet forming tools.

n Heat-resistant Casting resins The heat-resistant Biresin Casting resins belong to an independent product group. According to the product and application the necessary heat resistance is obtained by post treatment or by thermal running. Possible applications are vacuumforming moulds, injection moulds or other production equipment for higher temperatures.

n PUR- and Backfill-Casting systems Biresin PUR- and Backfill-Casting Systems are suitable above all for inexpensive solutions for production equipment by mass casting or backfill casting. For very light backfilling EP foam Biresin VP680 can be applied.

Biresin EP-Casting resins

Biresin Mixing ratio Colour Characteristics A B A [g] B G30 G30 10 F3 100 5 5 black all-purpose, workable, abrasion resistant, low shrinkage foundry patterns, metal sheet forming tools 5 7 F4 S10 F4 100 17 green low viscosity, high filler loading and high casting thickness backfilling in foundry pattern and mould making 1,700 70 24 1.6 D 90 112 51 D 86 71 48 2,600 180 48 G32 F2 G33 S15 100 6 black very hard, high abrasion resistance, very low shrinkage abrasion resistant ways F1 G37 F4 S12 100 10 5 5 grey high abrasion resistance, very low shrinkage facecasting layer for foundry patterns and diverse moulds 4,600 90 16-24 2.3 D 88 109 60 15,000 60 12 G49 L80 100 36 milky-white low viscosity, good impact strength and dimensional accuracy impact resistant moulds and mouldings for diverse applications 3,000 40 24 1.1 D 90 124 > 100* D 74 70 D 78 77 3,000 35 12-16 36 L80 R

Applications

Processing data (approx.-values)

Mixed viscosity [mPas] 40,000 40,000 30,000 50,000 Potlife [min] 60 60 45 20 Demoulding time [h] 12-16 24-48 24-48 > 12 6,000 45-60 16 1.9 D 90 120 95* 23,000 90 16-24

Physical data (approx.-values)

Density [g/cm] 2.1 Shore-hardness D 87 D 90 D 88 D 88 Compr. strength [MPa] 96 141 109 139 HDT [C] 67 85 63 65 D 89 105 85*

20

* after appropriate thermal treatment (refer to Technical Data Sheet)

Heat-resistant Biresin Casting resins

Biresin Mixing ratio Colour Characteristics A B A [g] B G36 L74 P7 100 10 6 8 grey workable, can be casted in thick sections, very heat resistantig vacuumforming moulds and other heat resistant tools G36 G38 G38 100 7 grey good flowing and degassing properties, very heat resistant G46 AL G46 100 25 grey easily workable, can be casted in thick sections, heat resistant

Applications

heat resistant moulds, e.g. vacuumforming moulds

Processing data (approx.-values)

Mixed viscosity [mPas] 18,000 6,700 pasty Potlife [min] 60-120 60-120 30 Demoulding time [h] 24* 24* 16-24* 10,500 120 16-24 1.8 D 90* 112* > 130* 3,000 20-25 12-16 1.7 D 87 91 80

Physical data (approx.-values)

Density [g/cm] 1.7 Shore-hardness D 89 Compr. strength [MPa] 130* 135* 130* HDT [C] 141* > 220* 141*

Biresin PUR- and Backfill-Casting systems

Biresin A B C A [g] B C G46 G48 G46 G55 100 100 25 100 beige opaque easily workable, can be easily workable, high casted in thick sections, filler loading, abrasion high dimensional accuracy and impact resistant master and core facecasting layer for metal sheet forming tools models, negatives, and foundry patterns foundry patterns 3,000 40 16-24 1.7 D 87 110 80 1,500 45-60 16-24 1.15 D 80 94 75 G48 G48 G55 G55 TE-Fller Al-Pulver 100 100 100 100 350 250 beige grey easily workable, can be casted in thick sections, high compressive strength backfilling for metal sheet forming tools and foundry patterns VP680 E670 E670 blowing agent 100 30 1-3 light brown unsensitive against humidity, slow blowing reaction very light backfilling

Mixing ratio Colour Characteristics

Applications

Processing data (approx.-values)

Mixed viscosity [mPas] Potlife [min] Demoulding time [h] castable 45-60 16-24 1.7 D 84 104 castable 45-60 16-24 1.7 D 84 90 castable 5-10 24 approx. 0.3 -

Physical data (approx.-values)

Density [g/cm] Shore-hardness Compr. strength [MPa] HDT [C]

21

Elastomeric Biresin Casting resins

The range of elastomeric Biresin PUR-Casting resins includes high-quality synthetic resin systems with a variety of shore hardness levels (Shore A40 D70) and possible applications.

n Elastomeric Casting resins for foundry pattern making The tough elastic types, are mainly used for foundry pattern making. Due to their very high resistance to abrasion, they are suitable for long-life surface layers of core boxes and match plates.

Elastomeric Biresin Casting re

Biresin
Mixing ratio [g] A B A B

n Elastomeric Casting resins for mould making The soft elastic types with very high elongation qualities are used for making flexible moulds (similar to silicone) and for castings made of the most varied of materials (even ceramic). The tough elastic products are suitable for more high-resistant moulds and mouldings as well as for wear-resistant coatings in special machine construction.

Colour Characteristics

Application

Processing data (approx.-values)

Mixed viscosity Potlife Demoulding time Density Shore-hardness Tear strength Elongation at break Abrasion resistance [mPas] [min] [h] [g/cm] [N/mm] [%] [mm]

Physical data (approx.-values)

Elastomeric Biresin Casting resins for mould making

Biresin
A B A Mixing ratio [g] B U1404 80 100 reddishtransparent U1404 U1434 50 100 light-beige 54 6 32 8 U1404 + U1404 + U1404 L 100 10 10 11 U1406 U1406 100 30 yellowishtransparent high elasticity and tear strength, insensitive to moisture ceramic industry, flexible moulds and components 2,800 15-20 > 16 1.05 A 55 12 450 15 ambertransparent U1303 100 35 colouredtransparent U1303 U 1402

Colour

reddishtransparent 3-component mix: Shore A 40-A 80 variable ceramic industry, flexible moulds and components 3,000-5,800 90 100 24 1.05 A 47 12 1,000 A 60 16 1,000 A 74 25 1,000 A 80 40 800

Characteristics

very soft, high elongation, low shrinkage ceramic industry, flexible moulds and components [mPas] [min] [h] [g/cm] [N/mm] [%] 3,000 25 24 1.05 A 40 7 > 600 3,700 20 > 16 1.3 A 55 9 > 600

rubbery, insensitive to moisture ceramic industry, moulds for concrete mouldings, flexible mouldings 7,500 45 16 1.05 A 73 9 280 A 81 18 400 4,000 25 16

Application

Processing data (approx.-values)

Mixed viscosity Potlife Demoulding time Density Shore-hardness Tear strength Elongation at break 60 100

Physical data (approx.-values)

22

esins for foundry pattern making

U1419 U1419 100 16 26 coloured-transparent abrasion resistant, impact and tear resistant, good flowability abrasion anCharacteristicst parts and tools, e. g. core boxes U1320 L U1305 B G55B 100 95 ivory favourable physiology, abrasion resistant, impact and tear resistant, good flowability abrasion and impact resistant parts and tools, e. g. smaller core boxes U1316 U1320 L 100 33 yellowish-transparent resistant, impact and tear resistant, long potlife, good flowability abrasion and impact resistant parts and tools, e. g. larger core boxes 38 light beige U1320 U1320 L U1303 100 38 light beige very abrasion resistant, very impact and tear resistant high abrasion resistant match plates and with larger dimensions 7,000 20 12-16 1.1 D 67 100 140 68 fast repair, smaller core boxes high abrasion resistant gelcoat for foundry patterns and core boxes spreadable 18 12-16 1.2 D 67 98 135 140 U1320 S Neu 70 green/white

2,800 6-7 1-3 1.1 A 98 (D 54) 68 375 90

3,500 25-30 24

550 6-8 12-16 1.2 D 65 80 190 130

4,000 25-30 16 1.1 D 60 83 150 120

7,000 10 >4 1.1 D 67 105 135 68

A 96 (D 50) 30 160 150

U1305 U1305 100 60 cream-white high abrasion resistance, can be accelerated by HC586 wear resistant coating, electronic encapsulation 2,300 15-20 10-16 1.2 A 89 27 300

405 G 55 100 33 beige high abrasion resistant, flexible wear protection (mats)

407 G55 100 53 grey high abrasion resistance, can be accelerated by HC586 wear resistant coating, electronic encapsulation, moulds for concrete 700 25-30 16-24 1.15 A 85 17 220

411 G53 100 48 beige processed by 2-component unit, fast curing flexible moulds, e.g. for edge casting

408 G55 100 66 beige processed by 2-component unit, high wear resistance flexible and wear resistant mouldings and coatings 2,300 / 40C 100-110 sec / 40C 1 / tool 50C 1.25 A 94 45 340

8,000 6-7 1 at 50C 1.25 A 66 6-7 240

800 1 1,5 1.1 A 87 21 90

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Biresin Adhesive and Filler systems

The Biresin Adhesive and Filler systems are specially adapted to SikaBlock boards. This relates to colour and mechanical-physical properties. This results in a similiar behaviour regarding machinability and subsequent use in application.

n Biresin Adhesives In the development of adhesives, special attention is paid to achieving a sufficiently high degree of adhesive strength and rapid curing.

n Biresin Filler systems The creamy-soft consistence of the filler systems results in easy application properties. They are also suitable for levelling, repairing and moulding of models and negatives out of Biresin Tooling resins, wood and metal etc. for model-, mould and tool making.

Biresin Adhesives
Biresin Mixing ratio Colour Characteristics [g] A B A B Kleber orange Kleber braun G53 G53 100 100 65 65 orange brown colour and mechanical colour and mechanical properties adjusted properties adjusted to M450 to M700 bonding of M450 [kg/m] [min] [h] 0.9 20 6-8 0.8 D 61 28 bonding of M650, M700 0.9 20 6-8 0.8 D 63 30

Application

Processing data (approx.-values)

Material consumption Potlife Setting time

Physical data (approx.-values)

Density [g/cm] Shore-hardness flexural strength [MPa]

Biresin Filler systems

Biresin Mixing ratio Colour Characteristics A B A [g] B Spachtel orange Spachtel braun Spachtel wei BPO-Paste BPO-Paste BPO-Paste 100 100 100 2 2 2 orange brown white good adhesion, non sticking and fast curing, easily to grind colour adjusted colour adjusted suitable for to M450 to M700 M1000 levelling, repair and modeling of surfaces M450 M650, M700 5 > 20 1.6 D 70 M1000 5 > 20 1.9 D 75

Applications

Processing data (approx.-values)

Potlife Setting time [min] [min] [g/cm] 5 > 20 1.3 D 58

Physical data (approx.-values)

Density Shore-hardness

24

* after appropriate thermal treatment (refer to Technical Data Sheet)

Power Adhesive Thix Power Adhesive 100 33 yellowish- transparent resistant to high mechanical stresses, good chemical resistance bonding of tooling boards 0.7 30 16 1.16 D 80 58

M60 S10 100 15 brown similar properties like M650, M700 bonding of M650, M700 0.6 15 7-8 0.7 D 69 32

G26 G26 100 100 beige very fast curing, good mechanical properties very fast bonding of model boards 0.7 3-4 45 min 1.1 D 70 40

G28 G26 100 100 beige fast curing, good mechanical properties fast bonding of model boards 0.7 7-8 2 1.1 D 68 41

Foam Adhesive colourless one component adhesive, humidity curing for M80, M150, M300

Fast Adhesive Fast Adhesive 100 60 blue resistant to high mechanical stresses, fast curing fast bonding and fast filler for tooling boards 0.7 3 1 1.2 D 83 85

HT Adhesive HT Adhesive 100 15 light green high temperature resistant, fast curing bonding and filler for M2010 0.7 30-35 16 0.7 D 75* 47*

0.1 open time: 10 6-8 0.1-0.2 -

Fast Adhesive Fast Adhesive 100 60 blue fast setting and very high mechanical properties fast filler tooling boards 3 1h 1.2 D 83

HT Adhesive HT Adhesive 100 15 light green high temperature resistant, fast curing filler M2010 30-35 16 0.7 D 75*

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Auxiliary materials
n Filling materials Filling materials serves for modification of properties of Biresin Laminating-, Multipurpose- and Casting resins, e.g. for improving the shrinkage and adapting the thermal conductivity. Especially on castings of higher volumes the material costs can be reduced.

Filling materials
Name Colour Delivery unit Description Aluminiumgrie silver to matt-grey 25 kg paper bag aluminium grit Aluminiumpulver (AL-Sprhgrie) silver to matt-grey 25 kg paper bag aluminium powder KR-Fller grob white 25 kg paper bag white granulated calcium carbonate KR-Fller fein white 25 kg paper bag white, fine granulated calcium carbonate LF-Fller white 20 kg paper bag lightweight powder, based on microsilicate mouldings with low density

Applications

backfill castings and backfill castings with parts with good thermal conductivity good thermal conductivity and good machinability and good machinability 1 - 1.5 G32 Resin : Filler (100 : 100) [g/cm] [mm] 2.7 0.6-1.2 1.0 G27 Resin : Filler (100 : 300) 0.75 0-0.07

light mouldings

light mouldings

Processing data (approx.-values)

Bulk density Mixture for example G46 Resin : Filler (100 : 100) 2.7 1.0-1.5 G46 Resin : Filler (100 : 80) 2.7 0.35-0.7 0.4 G27 LR Resin : Filler (100 : 100) 0.6 0.01-0.25

Physical Data (approx.-values)

Density Grain

n Surface pre-treatment High-grade release agents, primer and cleaner providing an optimal surface pre-treatment.

Surface pre-treatment (release agent, primer, cleaner)

Name Colour Delivery unit Sika Trennmittel 810 milky 0.7 kg 3.5 kg low viscosity, silicone free wax dispersion release agent for EP- and PURgelcoats and casting resins Sika Trennmittel 815 Quick milky 0.68 kg 3.4 kg low viscosity, silicone free wax dispersion with fast drying release agent for EP- and PURgelcoats and casting resins

Description

Applications

Processing data (approx.-values)

Material consumption [g/m2] - Brushed coats - Sprayed coats Drying time [min] 70 30 20-30 0.77 70 30 5-10 0.75

Physical data (approx.-values)

Density [g/cm]

26

n Additives Additives are added to Biresin systems to reach a specific thixotropy, thinning, acceleration or colouring of products.
TE-Fller grey 20 kg paper bag aluminium hydroxide powder light mouldings with good workability PVC-Brandgranulat grey 30 kg paper bag hard PVC, milled mouldings and backfill casting with low shrinkage

Additives (thixotroping, thinning, acceleration, colouring)

Name Colour Delivery unit Description Stellmittel T white 1.0 kg light weight, non dusty powder thixotroping of EP- and PURsystems Sikamoll clear-transparent 10 kg non-volatile softener flexibilisation of PUR-systems Biresin HC 586 clear-transparent 0.5 kg amine based catalyst reaction acceleration of some PUR-systems (e. g. U1305, G46) Biresin Farbpasten see below 0.5 kg colours: white, black, green, red, blue, yellow colouring of EP- and PURsystems

1.2 G26 Resin : Filler (100 : 250) 2.4 0-0.032

G48 Resin : Filler (100 : 150) 1.4 0-6 Applications

Sika Trennwachs 818 whitish 0.7 kg pasty wax dispersion release wax for EP- and PURgelcoats and casting resins

Sika Release LG colourless 1l semipermanent release agent, free from silicones and halogenes for EP-, phenol-, polyester- and vinylester resins in composite-, Aland steel moulds

Sika Mold Sealer colourless 1l polymeric resin in organic solvent blend for GRP moulds (polyester, vinylester and EP resins) and steel moulds

Icosit KC 330 Primer yellowish-transparent 3l low viscosity 1-componentPUR-system increasing of adhesion of PURsynthetic resins on metal and plastics

Sika Mold Cleaner colourless 1l

Sika Reinigungsmittel 5 clear-transparent 1 l, 5 l, 10 l

organic solvent blend

mild solvent blend

cleaning of mould surfaces in composite production

cleaning of tools and surfaces

50-100 10-15 0.79

70 > 30 0.73

> 30 0.75

50-200 60-120 1.0

0.8

0.8

27