The Manu-Cast 4-Stage Process

Manu-Cast Stage 1

"Seamless" Mass Cast

No joints or laminations
Replicates typical modelling/tooling board properties
Material waste minimised
CNC machining time significantly reduced
Good dimensional stability
Low shrinkage
Single pouring process

Manuplas currently have 2 polyurethane based formulations available. Manucast CPUB750 and CPUT1650. The first being for general purpose applications replicating the capabilities of a 0.7 – 0.8SG modelling board. The second is for performance critical applications replicating the capabilities of 1.6-1.8SG tooling board.

Currently under development is Manu-Cast Epoxy - a mass cast pre-preg solution.

Replacing the process of laminating individual mass produced boards, Manucast is a seamless production process.

How the process works:

1. Produce a cavity. This can be in the form of a simple box or to maximise the benefits of the process we utilise a “Lost Mould Process” type. This is the machining of EPS to produce a cavity slightly larger than the required dimensions of the finished product. The closer the form of the cavity is to the finished product, the lower the material waste is and the quicker the machining time. This cavity can either be produced in-house by Manuplas or supplied direct by the customer.

2. Mass Cast the pre-prepared box/cavity in a single pouring process.

3. Release the Mass Cast billet from the cavity. If no machining services are required, then the billet is best shipped to the customer in the cavity to give it better protection during transit.

4. Post Cure of the billet prior to machining. This service is optional depending on specific customer requirements.

Manu-Cast Stage 2

5 AXIS CNC machining

Simultaneous 5 Axis CNC router
Maximum bed size 3m x 1.5m x 0.7m
State-of-the-art CAM software
Machining capabilities for a diverse range of materials
Expertise in marine, aerospace and leisure industries

Market leading software

Manuplas is currently able to offer 5-axis CNC machining, with a maximum billet size of 3m x 1.5m x 0.7m high. Driven by market leading software, our expertise in CNC machining is evident in our completed projects spanning the marine, leisure and aerospace industries. Constantly updating their technology, Manuplas are committed to providing state-of-the-art solutions to customer needs.

Our specialist knowledge and experience of machining a multitude of materials gives customers peace of mind when defining their specification. Materials include:

Soft Foams

Polystyrene
Polyethylene
Polyurethane

Tooling Materials

Polyurethane Board
Polyurethane Fast Cast Resins
Filled Epoxy Resins
Epoxy Paste Systems
Polyurethane Past Systems

Specialist Materials

Polyurethane Syntactic
Epoxy Syntactic
Mass Cast/Filled Polyurethane Blocks

Plastics

Polyethylene
Polypropylene
Acrylic
UHMW
PVC
Fibre Reinforced Composites

Manu-Cast Stage 3

Mould Production

Closed mould technology
Innovative material solutions
Rapid turnaround
Fully integrated service

Manuplas has developed a number of strategic partnerships with specialist companies to enable the optimum customer solution. The quality of the finished mould is of the highest standard.

Manu-Cast Stage 4

Manufacture

Specialist in bespoke solutions
Innovative polyurethane composites
Contract manufacturing
Customer partnership