Development of a Prototype System for Suspending Ferromagnetic Particles in the Bio-Based FlowCast during Thick Pours - EcoPoxy Inc.

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EcoPoxy Inc. is a Manitoba-based company and the producer of the FlowCast bio-based epoxy resin made from renewable resources and used for a wide range of applications as a preferred alternative to the epoxy resins from fossil fuels. EcoPoxy also produces other resins including the SnowWhite, UVPoxy, GelCoat. EcoTrowel and BioPoxy 36. The FlowCast is a clear liquid glass-looking epoxy resin used specifically to build furniture but has also found applications in encapsulating objects, wall arts, sporting equipment and other casting projects. As part of the company's effort to significantly widen the areas of application of FlowCast through thoughtful designs, EcoPoxy is in the process of developing a system for suspending metallic particles in the resin during casting. The suspended metallic particles would form various patterns for an improved aesthetic appeal, thereby significantly widening the applications of the resin, especially in furniture manufacturing. EcoPoxy has taken initial steps in identifying some ferromagnetic particles that may be used. However, there is currently no manufacturing process or system for dispersing the particles for specific patterns and suspending the particles in the resin during the 20+ hours required for curing. In addition, there is a significant knowledge gap in how this may be done. Therefore, EcoPoxy requested to collaborate with the Technology Access Centre for Aerospace and Manufacturing (TACAM) at Red River College to conduct a comprehensive evaluation of potential technologies and develop a prototype system for suspending ferromagnetic particles in FlowCast (and other epoxies) while it cures, leaving behind a visible pattern. The approach to deliver this work would include the study of magnetic systems and arrays that can effectively disperse the metallic particles for specified patterns, and the design and construction of a prototype instrumented system for carrying out the actual work on representative castings. This project would culminate in the development of a prototype that can be further developed and scaled by EcoPoxy for production purposes. TACAM team will capitalize on the College's existing capabilities and expertise in design, 3D modeling, mechanical analysis, fabrication techniques, electromechanical systems and systems integration to deliver this project. Ecopoxy is an established innovative SME in Manitoba with a significant amount of commercial activities across Canada and throughout the world. The company has the capacity to implement and further advance the results of this project through commercialization. The College's TACAM team is looking forward to applying their advanced manufacturing expertise beyond the general manufacturing space, into the biomaterials industry. The team seeks to expand existing knowledge in design and advanced manufacturing with opportunities for new industries. The knowledge gained will benefit students/interns, research personnel and faculty and will be useful in future research engagements.