Large Tires

You don’t want a sticky mold when making these tires.

However, that is what Extreme Coating Solution’s client was fighting until we introduced them to Dyna-Tek’s nano-ceramic mold sealer and release coatings. After calling Extreme Coating Solutions, out of Kansas City, Missouri, a site visit revealed a 6,000 pound, 8 foot diameter tooling that needed surface treatment that would keep its lubricity despite the rigors of the molding process.

Tire Bladder Mold

Inherently, these tires are engineered for toughness, and with side walls over 8” thick; getting tires that are not releasing from the molds creates production throughput and efficiency declines as well as quality issues. However, it was the safety issues for the company’s workers that made solving this problem a top priority within top management of this company.

Dyna-Tek called on its certified applicator, Extreme Coating Solutions, to treat the tooling with Dyna-Tek’s DT-420 Mold Sealer and DT-6060 Mold Release coating products. Dyna-Tek’s 420 and 6060 coatings are:

  • Applied with a wipe-on process.
  • Can be applied on site provided the area is clean, controlled temps of 60 – 75 deg. F.
  • Air-cured. The first coat is dry to the touch within 30 min., but to achieve maximum performance properties, should air dry for 5 days. The top-coat, will air dry in 10 minutes, and can be put into production within 12 hours thereafter.

Ultimately, all coatings begin to wear off. The top coat; DT-6060 doesn’t stick to much; except itself. Meaning, it can be re-coated indefinitely to keep refurbishing its lubricity whenever needed. ECS trained our client’s maintenance staff so they can apply the top coat themselves!

For more information on this case study, click here.

Extreme Coating Solutions: Mold Case Study June 2017

Original Leaking Mold Surface

CHALLENGE: 50’ x 4’ Aircraft Spar Tool would not hold vacuum, and a small quantity of production parts from the Tool was still required.

Attempts to repair and extend the life of the mold thru various options had failed. If unable to repair the mold, the replacement cost would be $175,000, which was greater than the  value of the remaining parts needed to complete the production contract.

SOLUTION: Dyna-Tek (DT) Mold Sealer/Release System… Face side of the mold.

  • DT 2-coat sealer and mold release system is hand-applied and worked into the surface on the face side of the mold.
  • No silicone contamination.
  • Coating system adds no more than 4-8 microns, thus virtually no dimensional change to the tooling surface dimensions
  • Air-cure (preferably 4-5 days).
  • Covalent (molecular) bond. A chemical bond occurs at the molecular level with the composite substrate creating a chemical bond vs. a mechanical bond.
  • On-going “refurbishment” coats can be applied by our client’s Tooling Dept. on an “as needed” basis not only extending tool life, but keeping production pull quality high.
Extreme Coating Solutions: Mold Case Study June 2017

Refurbished Mold Surface

RESULT: Our team went on-site and repaired the mold; successfully sealing the surface and permitting this OEM to complete its production contract at a cost less than 10% of the mold’s replacement cost.

RECAP:

  • Zero vacuum
  • Mold sealed from the front side.
  • Once refurbished; vacuum measured 1.18 in. Hg in 5 min.

CONTACT INFORMATION

Extreme Coating Solutions | info@ecs-ww.com | (816) 381-9900

Case Study Challenge: Circular saw used to cut PEEK, glass-filled nylon and other materials experienced down-time, cut quality issues.

After seeing the benefits of he Dyna-Tek mold release coatings on their extruding dies, ZL began to look for other areas in operations where the DT products could improve production.

PROBLEM:

ZL Saw BladeOne area was their cutting saw station. The problem here was downtime and cut quality due to the heat build-up from the friction on the side walls of the saw blade as it cut through their large blocks of materials. Consequently, the blades would build up material over time which would lead to the operator stopping production to change out the blade.

Additionally, leading up to stopping the cut quality would continually diminish which left a lower quality appearance.

SOLUTION:

Dyna-Tek in conjunction with its approved applicator; Extreme Coating Solutions (ECS) coated one of ZL’s blades with the DT-420, forced cured it at 450 deg. F for 45 min. and then put the blade back in service.

Because the DYNA-TEK clear-coating has a ceramic-chemistry component to it, this accomplished two things:

  • The ceramic element results in dissipating the heat faster than an untreated blade.
  • The high-release, low coef of friction of the DT-420 meant less drag on the side walls of the blade, meaning less friction; and consequently less heat build-up as well.
  • Both of these improvements meant a cleaner cut, and higher quality appearance.
  • Down-time was reduced as each blade saw 6X’s longer service.

ZL’s FEEDBACK:

“When cutting with the DYNA-TEK coated 18” saw blade we get less side buildup and melting due to friction.  This has extended our saw blade useful life and improved the cut quality which is highly important to the customer.”

–        JOHN REYNOLDS, QUALITY CONTROL MANAGER

ZL Engineering PlasticsPRODUCTION CHALLENGE. ZL Engineering Plastics came to Extreme Coating Solutions with two production challenges:

  1. Improve the quality of extruded sheet, rod and tube.
  2. Increase the wear life of the coating on the tooling dies.

For years, ZL had tried various PTFE-based coatings, Chrome plated, and other options, in an effort to find a coating system that would last longer than the 4-6 weeks they were getting.

COMPANY OVERVIEW.

ZL Engineering Plastics is a high quality, American manufacturer of thermoplastic stock shapes for machined parts.  Their product range includes extruded sheet, rod, tube and cast parts made of a variety of materials including Acetal, PET, Nylon, PEEK, and Ultem®.

ZL’s high-density stock shapes are engineered to meet the strict standards required for subsequent machining into a variety of parts destined for use in industries such as oil and gas, electronics, machine parts, medical devices and others.

SOLUTION:  ECS Leveraged Dyna-Tek’s 2-Coat Mold Release System

PROCESS:

  • Blast off the original PTFE-based coating; but leaving a blast profile of approximately 6-7 microns.
  • Lightly hand-sand the blasted surface removing any loose particles left behind by the blast media.
  • Spray on, or if given proper training; hand wipe-on DYNA-TEK’s patent pending DT-420 base-coat. Allow it to flash off (20 min) and then force cure at 450 deg. for 45 min. or allow it to air-dry for 5 days.
  • Note: In some cases if the mold is in poor condition with a lot of porosity, it may require the use of our DT-898 to fill in those pores prior to applying the 420.
  • Apply our patented DT-6060 mold release, clear top-coat. Allow the 6060 to air dry overnight at 70 deg. or higher, and then the mold is ready to go again.
  • The resulting coating system is approximately 12-15 microns, very smooth finish with a coefficient of friction less than the PTFE-based coating it replaced.

CUSTOMER’S FEEDBACK:   

“When we move from PTFE-based coatings to DYNA-TEK, our sheet and rod quality improved dramatically.  With PTFE-based coated dies the appearance of our extruded materials had lines in them which created what a matte finish. With the Dyna-Tek system, the surface is far smoother, creating a very nice gloss finish that seems to only get better with age. This is an incredible difference and competitive advantage for ZL.

Additionally, because the Dyna-Tek coating is lasting at least 4x’s longer than the PTFE-based coatings, we have less downtime and and more production.  I would highly recommend any tooling that is currently coated with PTFE or other non-stick coatings be evaluated with DYNA-TEK.  The results and cost savings are impressive!”

–        PATRICK PHEFFER, PRESIDENT, ZL Engineered Plastics, N.A.

ADDITIONAL FEEDBACK:

“DYNA-TEK works well on old and new tooling alike.  The results have been nothing short of amazing.  Impressive surface quality and thus far, no re-coat required.  This saved us significantly and delivered a superior product. The PTFE-based coatings we used before would start to deteriorate after several weeks, while with DYNA-TEK we have yet to re-coat a set of dies due to it being worn out. Now when the dies reach 4X’s the time we used to run them, we pull them out as part of our overall maintenance program for the dies themselves; which ultimately extends their useful life.”

–        MARK DOUGLAS; PRODUCTION MANAGER, N.A. Operations.

For more information on Dyna-Tek’s Mold Release Products, visit www.Dyna-Tek.com or call us at 816-444-6266.