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Notes:
Talc and Calcium Carbonate are commonly used as extenders in resins and are considered to be non-abrasive. Zinc Borate is used as a flame retardant to qualify for UL 94V-O rating. It is considered to be slightly abrasive. Silica and Aluminum Oxide are often used to provide enhanced mechanical and/or thermal properties. They are considered to be highly abrasive.
There are numerous fillers that can be used to tailor the properties of a liquid plastic system prior to casting. Not only are these fillers used to increase the viscosity of your liquid resin system (thickening agent), but you will also affect the properties of the finished product. Some properties you can affect are cured density, strength, color, machinability, smoothness and sandability. Have a look at the summary below to learn about your different filler options.
Aluminum Powder - 99.7% Purity, 30 micron Aluminum Powder. Available in small or large quantity. For academia or industry. Economical.
Atomite - White calcium carbonate (CaCO3) powder used to give a marble-like appearance in castings. Can be used in polyester, epoxy or urethane systems. Reduces shrinkage and warpage, and improves machinability.
Cab-o-sil - Mostly used as a resin thickening (thixotropic) additive for polyester or epoxy systems. In general it is not used in urethanes, but it can be added to our EP1150 urethane to create a brush-on rubber for mold making or to use as a urethane adhesive.
Chopped Strand - Chopped fiberglass in 1/4" or 1/2" lengths, usually used to strengthen liquid polyester resins. Can also be used in urethane systems (in combination with fillite), to increase cured strength.
Fiberglass Flock - Used mainly in polyester systems. Not only can you thicken a liquid polyester to a paste-like consistency, but because fiberglass flock is actually ground glass, you can greatly increase the strength of the system.
Fillite - Grey powder added to liquid urethane systems as an inexpensive filler (takes up space and therefore you use less of the more expensive liquid system). Because of its density, it will neither float nor sink in a liquid resin. Cured castings that will float in water can be achieved if enough is added.
Microballoons - These hollow silica spheres behave similarly to Fillite, except that there is a higher tendency for the particles to float in low-viscosity systems. Its natural color is bright white. See detailed description, and advantages of microballon fillers (next page).
Talc - Addition of this ultra-fine, bright white powder reduces shrinkage and improves smoothness, abrasion resistance and temperature resistance in epoxy, urethane and polyester systems. Use thia filler in Polyester Gel Coat to make a smooth and thick, brush on mold face.
EP9009 - When added to epoxy, urethane or polyester, this liquid plasticizer blend increases cured toughness, resiliency and flexibility.
Molecular Sieves - If you suspect that you have a liquid urethane system (rubber, plastic, paint, coating) that has been contaminated with moisture, it is sometimes possible to reverse the effect through the addition of Molecular Sieves.
About Cenospheres, Microspheres:
Hollow Ceramic Spheres. aka: Micro-Balloons:
Cenospheres, derived from the inferno of coal-fired power plants, have been used for more than 30 years to improve the qualities of many manufactured products.
Cenospheres are hollow ceramic microspheres found in flyash, a natural by-product of coal combustion during the generation of electric power. Small and hollow, micropheres are used as functional fillers or extender in the manufacture of plastics, paints, resins, thermal coatings, epoxies, mastics; light weight aggregate for cement, ceramics and other construction products. Because cenospheres often replace mined materials, they can significantly lower production costs. Simultaneously, cenospheres can benefit finished product properties by increasing durability and functionality. Cenospheres are environmentally: 100% recycled.
Cenospheres are hard, inert, hollow, free flowing alumino-silicate microspheres. They are used to replace minerals and resins where the benefits may be as diverse as weight reduction, reduced friction, reduced shrinkage; improved insulation, fire resistance, flow characteristics and surface finish, or simply easier application.
Cenospheres are made up of silica, iron and alumina. Cenospheres have a size range from 1 to 500 microns with an average compressive strength of 3000+ psi.. Colors range from white to dark gray. They are also referred to as microspheres, hollow spheres, hollow ceramic microspheres, microballoons, or glass beads Lower viscosity hardness and abrasion resistance.
Cenosphere applications offer many benefits over mined materials, primarily cost and weight reduction. Of their many uses, microspheres are used as light weight aggregate in oil well cements, sound proofing, Thermal Insulation, interior and exterior paints, injection molding of plastics, automotive brake linings, and are even used by NASA in the nose of the Space Shuttle. Desirable properties include, controllable density for buoyancy, improved flow, excellent thermal insulation, light weight, and high strength. Environmentally friendly and 100% they aid not only the coal fired power plants control their pollution, but make their use Earth conscious.
Processed Cenospheres are chemically inert and exempt from classification as hazardous waste as determined by the United States Environmental Protection Agency. In addition they are considered "re-claimable" under the Resource Conservation and Recovery Act (42 USC §§ 6901-699-15).
Cenosphere Advantages:
Reduced weight, increased filler loadings, cost saving, improved flow characteristics, less shrinkage and warpage, less water absorption, buoyancy, flame retardance, chemical resistance, sound and thermal insulation, density management.
For Lure Makers: Microballon fillers added to Urethane Polymer Resins make the ideal material for casting/molding fishing lure bodies. This material combination creates, what I call; “Liquid Balsa Wood” When “A” & “B” resins are blended @100% by volume, they harden, inside the mold cavity, in just minutes to form a lure body with near identical qualities as balsa wood. Lure Makers can buy Polywood from Industrial Polymers Inc. pre-mixed.
Controlling the ratio of micro-balloons added to any resin can cause the resulting, blended material to float.
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