Method
Het CAST-FORM® gietproces: van matrijs tot eindproduct
KROV BV produces according to the self-developed and patented CAST-FORM® casting process with polyurethane for various applications in all kinds of shapes and colors. The polyurethane can be used as an edge finish, complete cover or for special technical applications.
In consultation with the customer, we discuss the package of requirements so that a customer-specific mold (average price between € 1,500 and € 3,000) can be made.
In most cases, the semi-finished product to be machined is supplied by the customer. After the mold is placed on the fixture table, the semi-finished product is poured with the customer’s desired color of polyurethane.
After a certain reaction time, together with the heat of the fixture table, this 2-component polyurethane transitions from liquid to solid form.
Then the mold is removed; the finished product is reworked, cleaned and inspected as necessary.
After a thorough quality check, the products are packed and prepared for shipping. Transport can be arranged both by KROV BV and by the customer.
The most important steps in our production process:
- Mold construction and control
- Mold preparation
- Colouring and checking polyurethane
- Placing the semi-finished product in the mold
- Closing the mold on the clamping table
- Injecting polyurethane into the mold
- Finishing and checking the product
- Assembling the end product
- Packaging of end product
Mold frame construction
After careful preparation, the steel part of the (customer-specific) mold is constructed using digital drawings.
Mold frame control
After the construction of the steel mold, it is checked again.
Mold preparation
In addition to the steel part of the mold, a forming mold (made of plastic) is needed to manufacture the final product. For the production of the mould a 1 on 1 model of the final product is needed. This model can be supplied by the customer, but can also be arranged by KROV BV. This model is prepared and lacquered in the desired structure. With this model, together with the steel frame, the flexible mould is cast.
Polyurethane coloring and checking
Before production can be started, the polyurethane has to be colored in the right color. Different types can be chosen, for example fireproof or transparent and different hardnesses. In addition, all RAL and NCS colors are possible. The color can also be matched to the color of the decor. The color is measured and recorded for future orders.
Placing semi-manufactured goods in the mold
It is very important that the mold be pre-treated with a release agent so that the polyurethane does not adhere to the mold. If necessary, the semi-finished product is still preprocessed.
Die is ready for the clamping table
After the semi-finished product is placed in the die, the whole is positioned so that when the final product is produced, the edge is the same all around in terms of thickness and width.
Close the die on the clamping table
After positioning, the clamping table can be closed and the die with the semi-finished product is pressurized.
Injecting polyurethane into the mold
After fixing the semi-finished product on the clamping table, the resulting channel (the space between the semi-finished product and the plastic mold) is filled with polyurethane.
Product finishing and checking
After the curing process, the mold is opened and the finished product is taken out of the mold. Now the finishing touch takes place and the product is checked for quality.
Component assembly
At the request of clients, KROV BV also takes care of the assembly of products. This can vary from a preparation in the manufacturing process to the complete assembly and packing in the desired packaging.
Finished product packaging
The best packaging method for the end product is determined in consultation with the client. KROV BV can draw on its wide experience of the various packaging methods.
