Denaco Imports Limited

The home of Polydur

Polydur Laminating System

Polydur Laminating System Polydur is a unique tooling system that provides lightweight, accurate laminates in a very short working time. Polydur has no health and safety aspects, is non toxic, has no smell and all its components are water soluble. Polydur was developed by Denaco Imports Ltd over ten years ago and is now used worldwide by a large number of industries and include tooling, automotive, aerospace, composites, art, theatre and film sets and many other diverse applications.

The system consists of an aqueous emulsion of acrylic resin (EM25) that is mixed with a specially formulated gypsum (LG) combination at a convenient mixing ratio of 100/50. This specific combination is the key to the accuracy and short demould time of the Polydur system and also the final physical properties and the suitability for many tooling applications.

The working techniques and characteristics are very similar to normal epoxy or polyester resin laminating applications and consist of a thixotrope mix for a surface coat (SGP/L) and a low viscosity mix for laminating. The laminating mix wets out glass fabrics and chopped strand mat, and very good results are obtained using 300gm Neomat. The average weight of a polydur laminate using 2 layers neomat is approximately 7.5kg/m². Two layers is suitable for most laminates and very large laminates can be reinforced with suitable stiffening ribs rather than extra layers of laminate.

The Polydur surface is a plastic type surface from which resin laminates or castings can be taken. However, the laminating system also bonds to conventional epoxy gel coats so epoxy faced Polydur laminates can be quickly produced.

The resulting laminates are de-mouldable in approximately 3 hours and can be used within 2 hours of de-moulding.

Tooling produced is available well within a working day.

Main Advantages

Much faster and easier than conventional resin laminating.
Faster, lighter and stronger than conventional gypsum systems.
Very short working times.
Very short lead times.
Accuracy.
Low co-efficient of thermal expansion.
High temperature resistance.
Economical.
No health and safety problems, all components water-soluble.

Typical Applications

Most laminating applications can be met with Polydur. There is no restraint on size, shape or substrate of model. However, appropriate sealing and mould release should be used.

Polydur laminates can be produced with a variety of surfaces dependant upon the application, e.g. epoxy, polyester, silicone rubber or Polydur surface.

Tooling applications include lay-up tools, holding jigs, prototype vacuum forming, drape tools etc.

Model applications include, concept models for automotive, aerospace, architectural and other engineering concepts. A Polydur surface can be painted after removal of mould release.

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