RTM Light

The Choice for RTM Light

Achieving a better part performance, a cleaner working environment and reduced styrene exposure and
emissions are major challenges for the composites industry. For that reason the need for improved working
processes has been a priority for manufacturers for many years, and has resulted in the development of
resin systems with low styrene emissions and low styrene content.

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lay up and Spray up (HLU/ SU) and press moulding, like Sheet Moulding Compound (SMC).

RTM Light is suitable for small production series of composites components

of miscellaneous shapes and sizes with low investment outlay.

2
The Process in Steps

RTM Light moulding processes are widely used in the composites industry for manufacturing high quality
components. These processes typically consist of the following steps:

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Resin trap

Resin injection

Tool
Vacuum pump

Resin

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RTM Light processes and allow easier decision making on process parameters
and key raw materials.

3
 %HQH¿WVRI570/LJKW

RTM Light, also known as Vacuum Assisted Resin Injection (VARI), uses vacuum to draw resin into the
mould, while at the same time the resin can be injected under moderate pressure.

Vacuum may also be used to clamp the two mould halves. The use of moderate pressures typically means
that a less heavy male mould can be used compared with Pressure RTM and SMC moulding processes.

Advantages Details
Considerably reduced styrene emissions System closed during injection

Capable of producing 2 smooth surfaces Gelcoat on both sides possible

Medium control part tolerance 6WLOOVPDOOWROHUDQFHVLQWKLFNQHVVGXHWRÀH[LEOH

upper mould
Lower labour intensity No hand labour during injection

Cleaner production More pleasant work environment (closed mould

system)
Improved GRP part properties and part Higher content and orientation of reinforcement
reproducibility compared to Hand lay up and possible
Spray up

Reduced cycle times possible For more complex products, thicker laminates,
sandwich constructions and large products
Filled systems can be used Combination of vacuum and pressure during
injection

Points of Attention Details

0RXOGDQGWRROLQJGHVLJQLQÀXHQFHWKHÀRZ Good tooling know-how required

Preform and reinforcement alignment is critical Design limitations (draw angles and radii)

Requires matched leak-proof moulds, higher 1HHGÀH[LEOHDQGWRXJKPDOHPRXOGDQGULJLG

mould/ tooling costs female mould compared with the single male
mould of Hand lay up and/ or Spray up

Higher reinforcement cost Typically more sophisticated fabrics and roving/

fabric combinations are used compared to
Spray up

4
Process Overview

The process requires a rigid female mould and

a semi-rigid male top mould. The mould closure
occurs by applying vacuum aided by simple
clamping mechanisms.

After preparation of the mould (with mould release,

optional gelcoat), the reinforcements are applied
and the mould is closed with a clamping system.

The resin is usually injected at low pressure (max. 1

bar) into a peripheral channel surrounding the part,
and vacuum is applied to an exit port near the centre
of the part.

The low net closing pressure and low internal

mechanical forces enable use of lightweight tools.
For that reason it is possible to use tools similar
(or adapted from) open moulding tools without
VLJQL¿FDQWH[WUDLQYHVWPHQW

When the reinforcement package is fully

impregnated with resin, the resin feed is cut
off. Still under vacuum, the laminate is left to
cure.

For larger series runs it is possible to work

with several female moulds and one semi-
rigid male top mould.

5
 Product Selection Considerations

When selecting and designing the optimised combination of resin and reinforcement, there are two
important parameters to consider:

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The overall laminate strength and stiffness are determined by the laminate thickness, the combination of
reinforcements and obviously by the resin matrix that holds the reinforcements. Further local strengthening
and stiffening may be obtained by using tailored fabric/ reinforcement combinations or by the inclusion of
ribs.

6
Resin Selection

Laminate mechanical properties are primarily determined by the reinforcement package. Heat
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by the resin system. Also longer term properties, such as water resistance, weathering resistance, heat
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Once the reinforcement package has been selected in line with both the end use and process
requirements, the base resin system is selected so that desired short term and long term properties can be
obtained. A wide range of base resins are available ranging from orthophthalic polyesters to Vinyl Esters
covering different end use requirements. Reichhold offers resins for standard applications as well as those
DLPHGDWKLJKHUKHDWFKHPLFDOUHVLVWDQFHDQG¿UHUHWDUGDQWEHKDYLRXU

T T
Flowtime

Geltime
T

Viscosity Temperature

T T
Viscosity

Viscosity
T

Temperature Filler loading

Viscosity
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WKHUHLQIRUFHPHQWSDFNDJHDQGWRROGHVLJQDVWKHVHZLOODIIHFWWKHEHKDYLRXURIWKHÀRZIURQW$YLVFRVLW\
ranging between 100 – 250 mPa.s. is often quoted as suitable for RTM Light.

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out by the glass reinforcement and can also cause rapid settling on storage. Flow, settling and surface
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additives.

Reactivity
The curing system of a resin plays an important part in part quality and production optimisation. The
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DOORZIRUSRVVLEOHPDFKLQHVWRSVGXULQJLQMHFWLRQ2QFHWKHPRXOGFDYLW\LV¿OOHGWKHUHVLQVKRXOG
ideally cure rapidly to allow shorter cycle times and rapid mould turnaround.

Reichhold offers resin systems meeting a wide variety of process requirements, including optimal
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systems for parts with improved surface appearance.
7
 Reinforcement Selection

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ODPLQDWHPHFKDQLFDOSURSHUWLHV,ILWLVUHTXLUHGWRSURGXFHDSDUWZLWKFRPSOH[GHVLJQDQGGLI¿FXOWDQJOHV
reinforcements with good drape-ability should be used.

When producing part with vertical surfaces, it may be necessary to attach the glass to the mould to avoid it
moving out of postion.

Flow through the reinforcement

Mould

@
5HVLQÀRZ

Flow layer
Reinforcement

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UHODWLRQVKLSEHWZHHQWKHÀRZSURSHUWLHVDQGWKHPHFKDQLFDOSURSHUWLHV)LQGLQJWKHULJKWEDODQFHEHWZHHQWKH
WZRLVRIWHQWKHEHVWVROXWLRQ)RUH[DPSOHRQHRUPRUHOD\HUVRIDPDWZLWKJRRGÀRZSURSHUWLHVDUHSODFHGLQ
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700μ

strand mat) will provide mechanical strength.

Flow properties
550μ

Combined reinforcement

Combined reinforcement/
Chopped strand mat
80
Flow Length (cm)

Chopped strand mat

60
40
20

0 15 30 45 60 75

Time (min.)

Dedicated reinforcement products are available for RTM Light processes including types where a
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8
Reinforcements for Improving Surface Finish

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QHHGVWRKDYHJRRGGUDSHDELOLW\DQGÀRZLQRUGHUWRDYRLGDLUHQWUDSPHQWQHDUWKHVXUIDFH$V\QWKHWLF
surface layer is recommended if a more resin rich surface layer is desired, or when parts without a gelcoat
will be exposed to harsh environments.

Core Materials

Inserts and cores can be placed in the mould prior to injection. Care must be taken in the design to ensure
accurate positioning and to ensure even part thickness on both sides of the core.

A good bond is required between resin and insert (chemical or mechanical), and this may require pre-treatment,
perforation or resin coating of the insert.

Core materials should have tapered ends/ edges to avoid the sharp transition between the sandwich and single
skin laminate. This sharp transition often results in resin rich areas which can lead to excess shrinkage and high
peak exotherms.

Incorrect radius

Correct radius

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speed on both sides of the sandwich core.

The temperature in the laminate can be relatively high during cure. Therefore the heat resistance
of the core material must be high enough to avoid collapse of the core during cure.

9
 Mould Setup

Channel to feed resin by vacuum or

light pressure or combination

Lightweight upper mould

(typically transparent FRP laminate)

Support frame for

easy handling
Vacuum clamping
seals and ports

Reinforcement
Gelcoat

The RTM Light method is typically considered cost effective for

production of 50-1500 parts per tool per year.

10
Mould Details

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For that reason they can be constructed lighter and less rigid in comparison with moulds used for Pressure
RTM or for SMC moulding processes. However similar design principles still apply. Also the moulds must
be robust enough to withstand production handling.

A RTM Light tool typically consists of a relatively stiff under mould (standard FRP mould, produced with
Polylite®3UR¿OH7RROLQJV\VWHPDQGDVHPLULJLGWUDQVSDUHQWXSSHUPRXOGW\SLFDOO\SURGXFHGZLWKDKLJK
quality Vinyl Ester resin).

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feed channel. Resin injection port(s) are located into the feed channel, and vacuum port(s) located near the
centre, all depending on injection strategy.

The use of semi-rigid tools relies on low injection pressures (between 1-3 bar). This avoids the risk of mould
deterioration or deformation that can lead to poor dimensional consistency.

Resin feed channel by vacuum or light pressure

or combination

Vacuum clamping

Lightweight upper mould (typically

transparent FRP laminate)

Closing seal

Rigid mould (typically standard FRP tool)

Resin vacuum seal

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between these seals.

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creating the necessary under-pressure to draw resin into the cavity.
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11
 Injection Strategy

One of the challenges in RTM Light is to choose the right ‘injection strategy’. This includes parameters
such as where to place the injection/ vacuum points and the choice of reinforcement. The placement of the
injection point must be carefully decided and is usually located at the furthest point. The geometrical centre
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SRLQWVFDQEHFRQVLGHUHGZLWKWKHREMHFWRIUHGXFLQJ¿OOLQJWLPHDQGDYRLGLQJDLUHQWUDSPHQW

Good seals
The closing vacuum seals must be perfectly leak-free and able to hold a stable vacuum pressure (-0.9 bar).
The seal between the piece cavity and the closure cavity must also be leak-free. The closure vacuum is higher
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EHLQJRRGFRQGLWLRQFOHDQDQGVHFXUHO\JOXHGLQWRFKDQQHOVLQWKHWRRO$OOUHVLQLQMHFWLRQDQGÀRZYDFXXP
attachment point must also be leak-free to avoid any air intake.

Feed channel
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not so large as to cause excessive exotherm. It must be of even dimensions to ensure an even distribution, and
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Thickness design
Extra care must be taken in the tool building process to achieve an accurate thickness. This is desirable
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with air entrapment. Several materials, often in combination, can be used to achieve the correct cavity
dimensions.

The surface aspect of the material used determines the rear surface aspect of the part. Sheet wax,
plywood, laminates are all used depending on the shape and importance of the rear surface aspect.
2IWHQDZHOO¿QLVKHGVPRRWKODPLQDWHLVDOVRDJRRGDOWHUQDWLYHJLYLQJDVWDEOHVXUIDFHDQGOHVVGLI¿FXOW\
around curves and angles.

Closing surface area

The clamping pressure must always be higher than the pressure inside the cavity. The closing surface
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The injection vacuum has to be lower than the clamping vacuum pressure. The fact that there is little
net closing pressure and low internal mechanical forces means that lightweight tools can be used.
This means that tools similar to open moulding tools or adapted from open moulding tools can be
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12
Equipment

The external vacuum closure seal is made of neoprene rubber of either a Wing shape or O ring type.

The internal seal which divides the piece/ cavity from the closure area should be made of silicone rubber to
improve cleaning and extend the life of the seal which is in contact with the resin. The most common shape
of this seal is the mushroom shape.

External Seal Internal Seal

Wing -or O - shape type Mushroom -or O - shape type

Vacuum Pump
For RTM Light a vacuum pump capable of pulling at least 1 bar is required. Pallet pumps are most commonly
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LVVXI¿FLHQW

In principle the RTM process does not consume very high resin volumes per shot. Multiplication of moulds
and tubes which may have minor leaks can quickly reduce effective pump capacity causing unwanted
pressure drops and closure problems.

Agitators and mixers

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resins are homogenous prior to use.

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FRVWHIIHFWLYH,IWKHWDQNLV¿WWHGZLWKKHDWLQJFDSDELOLW\WKLVFDQKHOSDFKLHYLQJFRQVLVWHQWSURGXFWLRQ
times. Typically this will releave the heaters on the injection machines which are often too small to be
fully effective.

13
 Equipment

Injection machines

RTM Light can be started simply using gravity feed, which requires no investment apart from the vacuum
pump. For small parts a simple pressure pot system attached to an existing compressor can also be used.
For larger production series and for increased part to part consistency a dedicated injection machine will
offer improved process control.

The type of part and the required cycle time will determine what type of kind of equipment is required.
For some products it may make sense to use several moulds and a larger vacuum pump, instead of faster
moulds cycling via an injection machine.

Useful accessories are:

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‡6WURNHFRXQWHU7KLVDOORZVDFFXUDWHFRQWURORIWKHLQMHFWHGDPRXQWIRUHDFKSDUWDQGNHHSDQH\HRQRYHUDOO
resin consumption.

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by avoiding resin spills between parts.

Demoulding Curing and Post Curing

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(with correct draft angles), in combination with the help of a release agent is desired.

It is important that the part is not demoulded before the part’s mechanical properties have reached a certain
level in order to avoid damage to the part. This can be expressed as a minimum level of cure after which
demoulding can take place. Barcol 934-1 values between 30 and 40 generally indicate an acceptable cure
OHYHOYDOXHVEHORZLQGLFDWHWKHSDUWLVLQVXI¿FLHQWO\FXUHGDQGPD\EHGDPDJHGGXULQJGHPRXOGLQJ

When the reactivity is too high (very short time from gel to peak), the peak exotherm temperature will also be
high which can result in damage of the part and or mould. High exotherm temperatures during processing
can leave micro-cracking or high residual stresses in the part and cause part discolouration. The tool surface
degrades also faster, causing the onset of gloss loss and surface cracking.

Curing systems for room temperature moulding of normal thickness pieces (2-5 mm) typically use cobalt/
amine accelerators systems and MEKP, AAP or blends. For thicker parts alternative peroxides giving
lower exotherm can be effectively used.

After de-moulding of the part, the state of cure has normally not reached the optimum level. It is therefore
always recommended to consider a post-curing period at an elevated temperature after de-moulding,
before the part is put into service or subjected to more rigorous handling.

14
Quality Control

Raw material control

Viscosity control

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manufacturers supply resins within a quoted viscosity range at a particular temperature using a
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PDLQWDLQFRQVLVWHQF\HVSHFLDOO\ZKHQ¿OOHUVRUDGGLWLYHVDUHEHLQJXVHG

Geltime and reactivity

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of the resin begins. It is recommended to make a quick check on geltime in the working area at
actual ambient temperature. This will require:

‡ Balance or graduated container (500/ 1000 ml)

‡ Pipettes (1-10 ml)
‡ Thermometer (alcohol or thermocouple)
‡ Stopwatch

Temperature control (workshop, resin, mould)

For increasing process consistency, ambient temperature in the workshop should

be recorded. This temperature will affect resin viscosity and curing, and therefore
should be kept as constant as possible for high part-to-part consistency.

‡ Thermometers (general use, immersion and surface thermocouple probes)

‡ Infra-red non contact temperature gun

Composite control after demoulding

The Barcol 934-1 hardness meter gives

a rough indication of the state of cure of
the part on demoulding by testing surface
hardness.

Even with the best quality control system

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can occur during processing, with defects
LQWKH¿QLVKHGSURGXFWDVUHVXOW
For advice about trouble shooting, please
contact your Reichhold Technical Service
representative.

15
 Design and Production www.ElcaMedia.com
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The information herein is to assist customers in determining whether our products are suitable for their
applications. Our products are intended for sale to industrial and commercial customers. We require
customers to inspect and test our products before use and to satisfy themselves as to contents and
VXLWDELOLW\ IRU WKHLU DSSOLFDWLRQV :H ZDUUDQW WKDW RXU SURGXFWV ZLOO PHHW RXU ZULWWHQ VSHFL¿FDWLRQV
Nothing herein shall constitute and other warranty, express or implied, including any warrant of
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inferred. All patent rights are reserved. The exclusive remedy for all proven claims is replacement
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Reproduction of all or any part is prohibited except by permission of authorized Reichhold

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