Molds for flexible urethane foam parts
are created using laminated epoxy tooling. A pattern of
the desired part is made by a skilled pattern maker. A parting
line is established for the mold. The desired surface finish
is applied to the pattern and set into the parting line.
An epoxy surface coat is applied and several layers of laminate
material are added until the mold achieves the appropriate
thickness.
Once the epoxy has set up, the parting line is removed and
the laminating process is repeated. When the second
half of the mold has set up it is demolded and the pattern
is removed. After an appropriate curing cycle and
a surface sealant is applied, the mold is ready for production.
In the paint booth area the applicator heats the molds up
to the specified temperature. Then the applicator
sprays 1-3 mils of in-mold coating paint onto the surface
of the mold.
For a more durable finish a Ride Hyde finish can be applied.
Once the Ride Hyde is cured the mold is then turned over
to the molders. There the molder inserts an armature
(if required). The armature uses precise pick-up points
to attach to the mold. The molder then finishes assembling
the mold. Once completed, the mold is charged with
a specified amount of urethane foam by the molder.
Once the foam is cured, the part is demolded and sent to
the trim/post spray department. There the parts are trimmed
of their flash and resprayed with urethane paint. In some
instances an additional coat of a 2-part urethane is also
applied, which includes a mildew inhibitor, a UV Stabalizer,
and other chemical resistancez. This process can accommodate
molded foam pads from 3/8” thick up to one foot and
beyond. Nearly any density and feel can be achieved.
