Articles that are produced by MAZURY Ltd. are made using contact method (hand lay up) base on forms with gelocte-fine polyester surface layer. Gelcote colours set by RAL, Reichhold, Ashland, Cryvalley standards.
Production abilities include to set production starting from technical documentation or samples supplied by customer, it is building the model, mould, prototype and release a series production. To put own models and moulds at the disposal is a frequent practice used by customers.

By the production we used to work with high quality materials of BASF, DSM, CRAY VALLEY, KROSNO S.C., ASHLAND, NORPOL, REICHHOLD, VERTEX, VIANOVA.

The products are often equipped with elements to in-laminate or fit up, there are construction metall bars, lattice, hinges etc.. In production we set also sandwich - technology (foam or core material - plates and slats, Coremat).

Due to long time experience of managing crew, it let us estimate very exactly the costs, alone after the product designation, simple sketch or verbal description. We also serve technical advices for our customers, regarding new projects.

The end prices for our products are determined after the calculation:

• model, mould, prototype price,
• kind and quantity of materials,
• degree of complexity,
• labour cost,
• series quantity.

{slider=Vacuum infusion}

Technology infusion has been known since the 70's of the last century and at the beginning it was used mainly for military aviation. Interestingly, only in recent years, this technique begins to be used on an industrial scale.
The process of making an infusion vacuum between "vacuum bag", and form. This makes it possible to obtain the effect, when the resin is nearly sucked, as a result of which a frame, which can be further processed. An essential element of the vacuum infusion technology to provide free transport for resin laminate structure. This is achieved by using a sandwich material, unidirectional fiber fabric or a special grid. Then the form of reinforcement is covered with foil. Negative pressure from 0.3 to 0.9 atmospheres provide accurate and consistent reinforcement throughout the supersaturation form.
The use of infusion entails a number of advantages that will want to consider when choosing this technology. First of all, it is a very large lamination process automation and a choice of different fabrics and resins. The infusion it considerably reduces the amount of resin (about 50% glass fiber, carbon or aramid and 50% resin), through which the laminate becomes a lot more durable. During the infusion process, a vacuum is produced, so that the fabrics are stacked and compression significantly reduces the volume. Another important advantage of using vacuum infusion technology is the elimination of air bubbles so that the product gets to the aesthetic value and becomes more robust. Vacuum infusion technology can be used both for the production of molds and finished parts from the composites. Most importantly, the process provides for substantial reduction in production costs.

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{slider=Hand lay}

Hand lay is the oldest method for creating composites and forms, but still the most common. Form (or when building a model form) after application of the separator (separator, wax) in the first place usually covered with gelcoat. Depending on the outer surface of which we want to use different types of gel coats.
The gelcoat is applied manually, by spraying or not exceeding 10 mm in thickness. It provides a suitable visual effect and creates a protective layer against the elements from the external environment (water, air, chemicals). Following the partial curing gel coat (after touching the gel coat is not on your finger, but you can see the imprint of the gel coat) is applied to a small layer of resin (then mixed with an appropriate curing agent). Then applied to each layer of reinforcement and again pervades the resin using a brush or roller. It is important to remove the excess resin and air bubbles are formed, so that the laminate becomes more robust.
The laminate is cured at room temperature, but this process can be accelerated by using an elevated temperature which also results in an increase in heat resistance of the laminate. Hand laminating technology is widely used due to its unlimited possibilities. It is used for small and large overall dimensions products, both simple, as well as part of a very complex shapes at low and medium serialization, and, for reasons of the low costs in the manufacture of prototypes.
Materials used:
Reinforcement: fiberglass, carbon, aramid or other synthetic or natural fiber resins: Most polyester or epoxy. Type of resin, initiator or curing agent must be chosen according to the time required for the device, according to the requirements on the strength, heat resistance, and chemical or special requirements (low flammability, low shrinkage for the production of forms, etc.), always taking into account the end use of the product.

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{slider=RTM (resin transfer moulding)}

RTM technology family is a group of technologies which includes techniques for the production of laminates such as light RTM (LRTM-Light RTM), vacuum-assisted RTM (VARTM vacuum assisted resin transfer molding) and classic heavy RTM

Injection is a technology that enables the production of large-size laminates. RTM technology has a solid and robust design forms, so that we are able to use the high pressure injection (2-10 bar).
Production of finished laminate RTM technology consists of the following steps:
The first step is to prepare forms for the production. It begins with a thorough cleaning and odłuszczenia form. Then applying several layers of separator (wax) and polished to obtain a smooth and even surface. In so prepared both forms (upper and lower) is applied to the gelcoat, which will function as a protective and aesthetic. Application can be carried out either by hand or by spraying. The next step is to match the reinforcement, which is to be built laminate. When put into mass production so. preform of reinforcing material. Reinforcing material based on glass or carbon fibers (carbon), or aramid, must have a structure that allows easy flow of resin in order to achieve complete saturation of the time.
Is then closed and sealed by the two forms of the pump is forced into the binder. Can be used as a binder polyester resins, vinyl ester, epoxy, methacrylate, and the other depending on the desired properties of the laminate. Solder is injected until it starts running out of the holes at the edges of the control form, which means that the reinforcement is fully saturated in the entire volume of the mold.
The last step is stripping and pulling the finished product and to prepare forms for the next laminate.
The big advantage of using RTM technology, is possible to obtain products with an even and smooth surface on both sides, and a relatively short production time (compared to the laminating manually). Use of the RTM technology greatly reduces styrene evaporation harmful, which greatly affects the quality of the work.
LRTM - LighRTM and VARTM - vacuum assisted resin transfer molding
LRTM and VARTM technology is a development of the RTM technology. Classic injection method has been extended to vacuum. With this combination, we can use a much lower pressure (0.4-1bar), which in turn, lowers the cost of production through the construction of less massive forms. Technology VARTM as the upper mold applies a vacuum bag, and both forms are LRTM made of composites.
Production of finished laminate LRTM and VARTM technology consists of the following steps:
The first step is to prepare forms for the production. It begins with a thorough cleaning and odłuszczenia form. Then applying several layers of separator (wax) and polished to obtain a smooth and even surface. Prepared for such a form (for LRTM two forms) is applied to the gelcoat, which will function as a protective and aesthetic. Application can be made either by hand or spray. The next step is to match the reinforcement, which is to be built laminate. When put into mass production so. preform of reinforcing material. Reinforcing material based on glass or carbon fibers (carbon), or aramid, must have a structure that allows easy flow of resin in order to achieve complete saturation of the time.
Then, the mold is sealed and the pump is injected through a binder. This can be done in two ways: the binder injected into the central part of the mold, a vacuum is applied around the perimeter of the mold, or an adhesive is applied to the duct at the periphery of the mold, a vacuum is applied in the central part of the mold.
Can be used as a binder polyester resins, vinyl ester, epoxy, methacrylate, and the other depending on the desired properties of the laminate.
The last step is stripping and pulling the finished product and to prepare forms for the next laminate.
LRTM technology is mainly used in the construction of boats and water sports equipment, but the feasibility of this method is an infinite number, for example: body parts, trailers, airplanes, etc. The VARTM method is used in the production of composites, where there is only one visible part of the laminate, eg overlay mirrors, bumpers, bonnet, etc.

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