Main molding process of artificial stone

Artificial stone can be manufactured using three primary molding techniques: casting, plate forming, and bulk block forming. Each method has its own advantages and is suited for different types of products.

1. Casting Molding: This is the oldest and most commonly used technique. It involves mixing the raw materials and pouring them directly into a mold, where they are then cured. In addition to producing flat panels, this method is also ideal for creating complex shapes such as bathroom fixtures, pipes, and grooves. The success of casting largely depends on the quality of the mold and the release agent used. Common mold materials include Sichuan FRP, stainless steel, and resin sheets. Since artificial stone made from unsaturated polyester resin has strong adhesion properties, choosing the right release agent is crucial. A good release agent should be light, neutral in pH, stable, have low affinity with polyester resin, not damage the surface gloss, avoid brush or spray marks, be easily washable with water, odorless, non-toxic, and cost-effective. Some release agents are derived from natural sources like palm oil, such as release wax or PVAI-based agents.

2. Plate Forming: This method is typically used for manufacturing medium to small-sized products. The mixture is pressed into a sheet (usually 4" x 1' in size), which is then solidified and polished. This technique offers a more uniform texture and is often preferred for decorative applications.

3. Bulk Block Molding: This process involves mixing the material into a thick cube or rectangular block, allowing it to cure, and then cutting it into smaller pieces. After that, the blocks are ground, polished, and finished to achieve the desired surface quality. This method is suitable for large-scale production and custom-shaped items.