Duplicate Moulding System

Duplicate Moulding System

Make your own dups. from original metal embossing dies.

 

Phenolic Duplicate Moulding System

Make your own dups. from original metal embossing die masters using the phenolic matrix board system. Bakelite duplicates can be produced in-house, at a lower cost, quickly and with great accuracy. Dups. are a perfect low cost solution for producing multiple embossing dies for repeat images on a print run.

  • Cut suitable phenolic boards to size.
  • Place phenolic boards in the moulding unit.
  • Place and spray suitable release materials onto and under the phenolic boards in moulding unit.
  • Spray the female metal die with release spray and then place image side onto the phenolic boards.
  • Place the correct bearers on either side on the moulding tray.
  • Slowly bring moulding press to the required pressure.
  • Allow the matrix board to cure under heat for the designated time.
  • Release the pressure.
  • Remove from the moulding press and allow to cool.
  • Trim off the access around the phenolic board.
  • You now have a male duplicate.

Repeat the process substituting the female metal die with the male duplicate and mould. The results will be a female duplicate and repeat making female duplicates till you manufacture the quantity required.   

 

Hermes Blue (IPF) Duplicate Moulding System – using Impregnated Polymeric Fibre Material

  • Place sheet of release film in moulding tray.
  • Place suitable type of heat and pressure stable counterforce or male metal die on the moulding tray.
  • Apply or spray on a suitable release agent on to the counterforce or use IPF release film.
  • Pre-heat the male die or suitable counterforce in the moulding press to the required temperate.
  • Place suitable bearers on either side of the male die or counterforce.
  • Cut the Blue IPF material to the required size and quantity and then peel the protective film from the IPF material.
  • Place the cut sheets of Blue IPF material evenly on top of the die.
  • Place release film over the stack of Blue IPF sheets.
  • Place a suitable Aluminium or Brass plate on top.
  • Slide the moulding tray into the moulding press, and close the platens to pressure.
  • Heat cure for the required time.
  • Remove from press and cool.
  • When cold, separate and trim as required.

 

Zeus Putty Duplicate Moulding System

  • Place male die or suitable counterforce on the moulding tray.
  • Apply or spray on a suitable release agent on to the male die or counter.
  • Pre-heat the male die or suitable counter in the moulding press to the required temperate.
  • Place suitable bearers on either side of the male die.
  • Cut the required number and or size of Zeus (DP) material to and peel the protective film.
  • Place the cut pieces of DP material evenly on top of the die.
  • Place release film over the DP putty and an Aluminium or Brass plate over the film.
  • Slide the moulding tray into the moulding press, and close the platens to pressure.
  • Heat cure for the required time.
  • Remove from press and cool under pressure.
  • When cold, separate and trim as required.

 

Embo-Therm*

A thin translucent foil, that’s applied to the make-ready and forms under pressure and heat created by the printing and or embossing die to create a counterforce. This product has depth limitations but multiple sheets and or multiple layers in the required area can be applied.

The Embo-Therm foil is available in 0.15mm and 0.25mm thick only. It is a very easy and quick system to use but is not normally pre-prepared. Embo-Therm is normally prepared and made by the machine operator using the hot foil press just before use.

 


Icarus (PM) -Paste system*

A paste which hardens completely in around 60 minutes under the pressure of the embossing die to create a counterforce. Before completely curing, the platen needs to be opened and the access material cut away. This system is suitable for large dies and a few multiple small dies.