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SPRAY UP

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Spray up

BFG Architecture uses a variety of methods to produce FRP parts. Our experienced engineers will select the best method for your project based on factors such as production volume, parts dimensions, budget, and other requirements. 

Our extensive experience with spray up moulding enables us to produce innovative and cost effective parts for our customers, including truck bodies, car bodies, and rolling stock parts.

The process is best suited for low volume requirements (less than 1,000 parts per year) where a one-sided finish is required. Since it produces a heavier, resin-rich laminate, it is better suited to parts which are produced mainly for aesthetic purposes.

Process
Spray up utilises a chopper gun which sprays catalysed resin and chopped glass fibres simultaneously. The multi-end roving is fed to the chopper gun from a creel that contains several thousand feet of gun roving. This multi-end roving is cut or chopped by the action of the spray gun into strands ½ inch (12mm) to 1 ½ inches (36mm) in length and combined with a spray of resin immediately in front of the gun nozzle. The saturated glass/resin matrix is then deposited on the mould surface. Multiple passes build the laminate to the specified thickness. As in the hand lay-up process, consolidation by hand rolling is required to compact the laminate and remove entrapped air. Also as with hand lay up, the ratio of glass fibre to resin is critical.

Materials options
Resins: Primarily polyester 
Fibres: Glass roving only
Cores: None. These have to be incorporated separately

Advantages
- Spray up can be faster than hand lay up in some instances, especially in the case of complicated shapes. 
- The process is ideal for low volume parts (less than 1,000 per year).

Limitations
- Since spray up uses only chopped strand mat with no higher strength woven or knitted fabric, it produces a heavier, “resin rich” laminate with lower 
physical properties.
- Only short fibres are incorporated which severely limits the mechanical properties of the laminate. 
- Resins need to be low in viscosity to be sprayable. This generally compromises their mechanical and thermal properties.

Applications
- lightly loaded structural panels, e.g. caravan bodies, truck fairings, bathtubs, shower trays, some small dinghies.

Contact us today so we can begin discussing your project needs.

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About BFG

For over 40 years, BFG has been a global leader and pioneer in composite design, engineering and manufacturing, with over 2,000 people and 15 production facilities worldwide – and a total commitment to quality and innovation.
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P.O. BOX 26197, MINA SALMAN,
KINGDOM OF BAHRAIN
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+973 1772 7063
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ideas@bfginternational.com
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  • Home
  • PRODUCTS
    • Building Envelopes
    • Building Facades
    • Primary Structural Roofs and Ceilings
    • Domes and Cupolas
    • Suspended Ceilings
    • Shading Elements and Screens
    • Interior Architectural Elements
    • Complex Formwork
    • Specialty Architectural Finishes
  • Projects
  • Materials
    • Introduction to composites >
      • What are composites
      • Fire safety performance
      • LEED certification
      • Sustainability and composites
      • History of composites
      • Famous architectural projects
    • Fiber Reinforced Plastic (FRP) >
      • Introduction to FRP Composites
      • Benefits of FRP composites
      • Materials Systems >
        • Matrix Reinforcements >
          • Aramids
          • Carbon fibre
          • E-Glass
          • S-Glass
        • Resin Systems >
          • Polyester Resins
          • Epoxy Resins
          • Phenolic Resins
          • Vinyl Ester Resins
        • Cores
      • Processing Technologies >
        • Open vs Closed Moulding
        • Contact moulding
        • Spray up
        • Light Resin Transfer Moulding (LRTM)
        • Resin Transfer Moulding (RTM)
        • Press moulding
        • Vacuum bagging
        • Vacuum Forming (Thermoforming)
        • Vacuum infusion
        • Sheet moulding compound (SMC)
      • Tooling and Pattern Making
      • Composites in architecture
    • Glass Reinforced Concrete (GRC) >
      • Introduction to GRC
      • Properties of GRC
      • Benefits of GRC
      • GRC in architecture
    • Ultra High Performance Concrete (UHPC) >
      • Introduction to UHPC
      • Benefits of UHPC
      • UHPC in architecture
  • About
    • About BFG
    • Media >
      • ​Media resources
      • Downloads
    • History
    • Certification
    • Careers
  • BFG GROUP
  • Contact