Fully recyclable composite mold incorporates Arkema Elium resin

Glass fiber-reinforced thermoplastic boat mold. Photo Credit: Arkema

In collaboration with milling and tooling company Merritt Precision (Merritt Island, Fla., U.S.), a Correct Craft company, Arkema (King of Prussia, Pa., U.S.) unveils its first entirely recyclable glass fiber composite mold using Elium liquid thermoplastic resin. The recyclable resin has been meticulously tailored for infusion processes of sizable components with low viscosity, long reactivity and a low exothermic reaction. While its use extends to diverse mold types, Elium resin is particularly suited for the marine sector, catering to the fabrication of composite watercraft.

Following IBEX 2023 in Tampa, Fla., U.S., Elium will be made commercially available. “The qualities inherent in the fully recyclable composite mold are not only beneficial for the ecosystem but also meet the needs of our manufacturing process,” Greg Warren, Merritt Precision’s technical director of operations, says.

Industries spanning marine, wind energy and transportation sectors, among others, rely on composite molds for production component manufacturing. These molds are predominantly fabricated from thermoset resins. Although they meet manufacturing requirements, their use is confined to a specific number of parts or years, averaging around four years before replacement. This conventional practice, says Arkema, creates substantial landfill waste, as the non-recyclable thermoset resins are commonly disposed or discarded.

Elium resin delivers attributes like those of thermoset resins while granting the recyclability advantage, enabling retired mold laminates to be reused to make new tooling or marine products themselves.

“Elium resin consistently forges pathways to solutions and opportunities in the marine industry and we are excited to present our progress in sustainability in partnership with Merritt Precision,” Nicolas Valloir, business manager at Arkema, says. “This innovation reflects the shared values and commitment of our respective companies in shaping a more sustainable collective future.”