Development of closed fiberglass molding process

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Ashton Pools, Ponds & Spas Inc., located in Kitchener, Ontario, is the manufacturer and installer of quality fiberglass pools. Ashton mainly employs fiberglass for inground pools due to many advantages such as low maintenance, durability, compatibility with salt systems, energy efficiency, low chemical usage, and etc. Currently fiberglass pools are manufactured using an open mold process, where 3 to 4 layers are formed by spraying fiberglass mixed resin onto an open mold, and curing them, one layer by one layer. However, small pores are frequently introduced between and inside the layers and thickness variation is significant across the plate. To address these problems, Ashton plans to develop a new closed mold process where fiberglass and resin are infused into the closed space between male and female molds so that curing happens in the controlled environment with vacuum and/or temperature applied. It is expected that the new process can greatly reduce pore formation, help achieve uniform thickness, and improve material properties. However, since mechanical and failure properties of fiberglass change with various parameters such as vacuum pressure, curing time, plate thickness and temperature, the relationships between these parameters and the properties should be carefully investigated and determined to apply the new process to actual manufacturing. Therefore, main objectives of this project are to investigate the variations of mechanical and failure properties of multi-layered fiberglass with respect to various parameters in closed mold process, to develop an optimum design and process method for fiberglass pools. MADE-IN-CANADAs by small- and medium sized manufacturing companies are the most important sectors in Canadian economy. Ashton has a vision to develop the best products and export them to USA and worldwide, and the successful completion of this project can greatly help the company to achieve the vision with better pricing, improved quality, increased competitiveness and productivity. This will help strengthen the Canadian economy through job retention and creation in the small- and medium-sized manufacturing sector.