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Imagine being able to inject liquid balsa wood into a mold. Three minutes later; it is a rigid, 3D, lure body......
The use of Meter-Mix-Inject equipment in combination with selected A-B Urethane Polymer Compounds is the key that unlocks unlimited possibilities for Lure Makers. They are the heart of the Micro Factory, and very affordable for a small business start-up. This is the stuff the large, commercial lure manufacturers don’t want you to know.
Meter-Mix-Dispense (Inject) Systems:
Many assemblers (lure makers) turn to A-B Compounds (multi-component materials) for improved quality, productivity and efficiency. Acrylics, epoxies, silicones, urethanes, polyesters, and other A-B Compounds (aka thermalsets, or RTVs - Room Temperature Vulcanizing) have a number of performance properties often not available in single component materials. Such as: High pressure injected thermal plastics.
A-B Compounds offer faster handling and cure times, and a variety of formulations to meet a growing number of applications.
The rate of cure and cure characteristics are primarily controlled by the chemistry, whereas single-component materials rely on some part of the environment to cure. A-B Compounds are usually less expensive and perform comparable to or better than conventional thermal plastics. This is very evident in the making of floating, ballast controlled, or zero buoyancy fishing lures.
The electronics industry uses a wide variety of A-B Compounds as well. For instance, most potting and encapsulating applications for vibration protection, environmental protection or electrical isolation use two-part materials. Other heavy users of A-B Compounds include cultured stone manufacturers, theme parks, movie set builders, model builders, art reproductions, and water-craft manufacturers.
Manual vs. Machine:
Assemblers face unique challenges when blending and dispensing multi-component materials.. Correctly measuring the amount of A and B material so you have the right ratio is very important. Too much or too little can result in inconsistent performance, poor quality and excessive cost. Fortunately, a wide variety of manual and automated systems are available.
A-B Compounds can be mixed by hand, with a process similar to making cookie dough. Hand mixing requires weighing specific amounts of catalyst and base. After the two are measured, the mixing must be consistent to ensure correct curing. And, dispensing from a hand-mixed vessel can be awkward and wasteful.
For manufacturers who are trying to prototype a new product or initiate limited production runs, hand mixing is often utilized and can be somewhat cost effective, however, hand mixing results in wasted material, operator exposure to potentially toxic materials, poor ratio control and subsequent curing anomalies. Hand mixing is unreliable, not repeatable and usually produces excess waste. Hand mixing, depending upon the application, has a labor cost and material cost.
Automated metering, mixing and dispensing (injecting) systems offer an alternative to hand mixing that provides precise ratio control, improved mixing, little or no wasted material and limited exposure to toxics. Meter-mix systems allow assemblers to correctly measure the amount of A and B material to achieve the right ratio.
A less expensive alternative to meter-mixing equipment is dual-cartridge dispensing, which uses handheld dispensing guns. The easy-to-use plastic cartridges isolate the user from the material, the material is on ratio and mixing is achieved by a static mixer.
This process is as easy as dispensing a tube of household caulk. Cartridges eliminate the need for expensive meter-mix equipment while maintaining the principles of meter-mix. Because dual cartridges are very mobile. Capacities range from 50 to 1,500 milliliters, but most assemblers prefer 200 - or 400 -milliliter cartridges. Cartridges typically can't be reused and must be disposed of.
Mixers can be either static or dynamic. Static mixers have no moving parts. They contain fixed, geometrically shaped elements that act as flow-splitting and shear-energy-creating devices for the materials that travel through them. Static mixers are usually either plastic or metal. They work well if the ratio and viscosity ranges of the two materials to be mixed are not too wide.
Static mixers serve as in-line mixers--the components to be mixed are pumped through the mixer and emerge out the end totally mixed. They can be used with both two-component machines and cartridge applications. Disposable static mixers are more popular than they were 5 years ago, because of the proliferation of two component materials. Health and environmental issues, such as worker exposure to the materials themselves and the solvents needed to clean them off hands, tools and equipment, have also contributed.
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