1. Thermoset Resins in Production Boatbuilding September 11, 2006 Joe Parker Product Manager, Pro-Set Inc. PO Box 656 Bay City, MI 48707 888-377-6738 parker@prosetepopxy.com Presented at a meeting of the Thermoset Resin Formulators Association at the Hyatt Regency Montreal in Montreal, Quebec, Canada, September 11 through 12, 2006. This paper is presented by invitation of TRFA. It is publicly distributed upon request by the TRFA to assist in the communication of information and viewpoints relevant to the thermoset industry. The paper and its contents have not been reviewed or evaluated by the TRFA and should not be construed as having been adopted or endorsed by the TRFA.

2. Thermoset Resins in Production Boatbuilding TRFA Fall 2006 September 11, 2006 Joe Parker Gougeon Brothers Inc.

3. Abstract This presentation will provide an overview of the current manufacturing processes and polymer resins used in the marine industry. Historical perspective and trends looking forward are also included.

4. Historical Perspective Resin Types Processes Transitional Phase Driven by Regulation Customer Performance Requirements Resin Choices Process Choices

5. Processes Contact Mold / Open Mold Vacuum Bag Resin Infusion

6. Resin Choices Polyester Vinylester Epoxy

7. Processes Contact Molding Wet Preg – Vacuum Bag Resin Infusion

8. Contact Molding bucket and brush Advantages Low cost No new equipment No additional training necessary Disadvantages minimal mechanical properties gain no control of resin content excess resin use / cost no labor savings

9. Closed Molding Vacuum Bagging Resin Infusion RTM RTM light

11. Vacuum Bagging ( What is vacuum bagging ?) The process of using atmospheric pressure to consolidate or clamp a laminate A membrane is sealed to the mold, and air is evacuated from under membrane Atmospheric pressure presses on membrane, squeezing laminate between mold surface and membrane

13. Advantages of vacuum bagging Apply uniform pressure over entire laminate surface Remove excess resin Help remove entrapped air Contain any emissions Can conform to almost any shape

14. Vacuum Bag / Wet - Preg Impregnator or roll coater wet - out Advantages Saves labor Good mechanical properties in laminate Excellent resin content control Good core bonding Disadvantages Equipment cost Equipment clean - up Training required

15. Resin Infusion (how does it work) Dry laminate stack placed in mold Vacuum bag installed and checked for leaks Resin allowed to flow into laminate under bag using atmospheric pressure to push resin

16. Resin Infusion Advantages Very good resin content control Good laminate properties Very clean / handle dry fabrics & core Can include secondary structure Disadvantages Training required License may be required Some additional resin waste Additional disposable materials

19. Resin Choices and Characteristics Polyester (PE) –Least expensive –Open Molding primary process –Resin infusion becoming popular –High VOC –Shrinkage is an issue –Toughness and Fatigue resistance in question

20. Resin Choices and Characteristics Vinylester (VE) –Higher price than PE – lower than Epoxy –Some contact molding –Used as skin coat resin with PE hulls –Resin Infusion most popular with VE –Better Fatigue resistance and Toughness –High VOC –Shrinkage

21. Resin Choices and Characteristics Epoxy –Most expensive Boatbuilding resin –Generally used in higher performance craft Often with carbon and S-glass –Can be used for Resin Infusion –Best fatigue resistance and toughness –Vacuum bagged laminate creates lightest structure

22. Summary Resin cost is small portion of part cost Cost of fibers and cores will continue to rise about equal to resin Closed molding here to stay and growing Customers demanding lighter, more durable boats