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CONTENTS
 Fiber glass introduction
 Application
 Door mould preparation
 Actual door production
 Advantages
 Disadvantages
Fiber Glass Doors
 Its a reinforced Plastic where the reinforcement fiber is
specifically glass fiber.
 The glass fiber may be randomly arranged, flattened into a
sheet (called a chopped strand mat), or woven into a fabric.
 The plastic matrix may be a thermosetting plastic – most
often epoxy, polyester resin – or vinylester, or a
thermoplastic.
Chopped Fiber Glass
Woven Fiber Glass
Fiber glass application
 Car bodies
 Boats
 Insulation in homes
 Chairs
 Surf boards
 Roofs
 Doors
Fiber Glass Door
Manufacturing Process
MOULD PREPARATION
 Starts with a real wood door
 Different panels are created
 The wood is scratched with a wire brush to expose the
grains
 the panels of the door are assembled in a special fixture
 The dimensional accuracy is checked with a laser
 Special formulation of silicone is poured onto the wood
Panels of the wood door
Silicone layers
Nickel shell (mould)
 Cured overnight
 The silicone picks up the definition of the wood grains
 Mirror image copy of the door is created
 Another formulation of the silicone is injected between this
silicone pad and thin sheet of steel
 The silicone sheet produced is thinner for better transfer of
heat for the next process
 Chemical vapour deposition of Nickel vapour
 The nickel shell produced has all the detail of the original
wood door
 This nickel shell is used as the door moulds
Fiber glass doors
manufacturing
 The fiber glass dough is flattened and cut into strips
 Strips are placed in the mould , heated and pressed
 It is then peeled off and the edges are trimmed
 The doors panels are stained to expose the transferred wood
grains
 The thickness is checked using a dial gauge
Dough like GRP
Door Press
Insulation and press
 Rollers apply glue to the external frame
 These frames are glued to the ends of the fiberglass door
skin
 The door arrangement is squeezed though rollers
 The glue is cured over 24 hours
 The doors are placed in an insulated press and pressed
 Poly urethane insulation foam is injected into the doors
 The fill holes are capped to prevent the foam from
overflowing from the vent holes
Advantages
 High strength (due to presence of multiple materials)
 Durability
 Good looks – appearance
 Security
 Warranty
 Insulation
Disadvantage
 PRICE!!
 Standard sizing
Conclusion
Convincing solid alternative to Wood
Embossed wooden grain – convincing knock offs (Imitations)
Thank You

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Composites ppt

  • 1.
  • 2. CONTENTS  Fiber glass introduction  Application  Door mould preparation  Actual door production  Advantages  Disadvantages
  • 3. Fiber Glass Doors  Its a reinforced Plastic where the reinforcement fiber is specifically glass fiber.  The glass fiber may be randomly arranged, flattened into a sheet (called a chopped strand mat), or woven into a fabric.  The plastic matrix may be a thermosetting plastic – most often epoxy, polyester resin – or vinylester, or a thermoplastic.
  • 5. Fiber glass application  Car bodies  Boats  Insulation in homes  Chairs  Surf boards  Roofs  Doors
  • 7. MOULD PREPARATION  Starts with a real wood door  Different panels are created  The wood is scratched with a wire brush to expose the grains  the panels of the door are assembled in a special fixture  The dimensional accuracy is checked with a laser  Special formulation of silicone is poured onto the wood
  • 8. Panels of the wood door
  • 11.  Cured overnight  The silicone picks up the definition of the wood grains  Mirror image copy of the door is created  Another formulation of the silicone is injected between this silicone pad and thin sheet of steel  The silicone sheet produced is thinner for better transfer of heat for the next process  Chemical vapour deposition of Nickel vapour
  • 12.  The nickel shell produced has all the detail of the original wood door  This nickel shell is used as the door moulds
  • 13. Fiber glass doors manufacturing  The fiber glass dough is flattened and cut into strips  Strips are placed in the mould , heated and pressed  It is then peeled off and the edges are trimmed  The doors panels are stained to expose the transferred wood grains  The thickness is checked using a dial gauge
  • 17.  Rollers apply glue to the external frame  These frames are glued to the ends of the fiberglass door skin  The door arrangement is squeezed though rollers  The glue is cured over 24 hours  The doors are placed in an insulated press and pressed  Poly urethane insulation foam is injected into the doors  The fill holes are capped to prevent the foam from overflowing from the vent holes
  • 18. Advantages  High strength (due to presence of multiple materials)  Durability  Good looks – appearance  Security  Warranty  Insulation
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  • 22. Conclusion Convincing solid alternative to Wood Embossed wooden grain – convincing knock offs (Imitations)