|Female Mold Types|
For many types of open mold casting, both a male and female mold are required. Examples are vanity bowls, bathtubs and some accessory products. Female molds are the mold shape that forms the underside or backside of a cast cultured marble or solid surface product. When properly positioned with the male mold, it creates the cavity that is filled by matrix to form the cast part.
Gruber Systems has developed a multitude of different kinds of female options to satisfy the diverse needs of its customers. However, because there is such a diversity of needs and production methods, one type of female hat may work better than another, for different customers, including:
Gruber Systems has developed a multitude of different kinds of female hats to satisfy the diverse needs of its customers. However, because there is such a diversity of needs and production methods, one type of female mold (or "hat") may work better than another, for different customers.
Female mold options can generally be categorized as a female (shown immediately below), but there are alternatives that you should consider before purchasing a female mold.
Floating Fiberglass Female (FFF)
Like the male mold, Floating Fiberglass Female molds are made entirely of fiberglass, providing the ultimate in strength, durability, and reusability. Simply apply a coat of mold-release wax to the clean, inside surface of the hat before each casting to assure easy release. The FFF will produce a smooth surface on the underside of the bowl. "FFF" molds are dimensionally stable and result in a uniform wall thickness and smooth surface to the underside of the bowl or other casting, and are durable and excellent reusability. In addition, these female molds include a generous fiberglass flange around the hat to enable it to rest solidly on the first pour matrix. The fiberglass female must be clamped to the male mold prior to casting the product.
To order a Floating Fiberglass Female, place the letters "FFF" in front of the series designation of the bowl with which the hat will be used. For example: If ordering a Floating Fiberglass Female for a series "N" bowl, the order would read "FFF-N."
Full Cover Fiberglass Female
A Full Cover Fiberglass Female mold offers all the advantages of strength, durability and reusability as the Floating Fiberglass Female (FFF) above, but with two additional advantages.
The full-cover flange length permits complete coverage of the male mold and is the basis of the "single pour" production system used in many high volume marble plants. All Full Cover Fiberglass Females are adaptable for use with Gruber's G-Clamp clamping system, an optional feature available on many Gruber modular vanity molds.
Note: Most females must be ordered separately in addition to the male mold. Refer to the Mold product section, and the various female mold and hat options will be listed with each mold.
Gruber also produces "hats - which are not as durable as a female mold shown above, but offer unique advantages:
Two types - Permanent Hats, and Reusable Hats
Permanent Hats become a permanent part of the marble product, providing a finished underside which requires very little, if any, additional finishing. The hat is set in place on the un-gelled first cast immediately following vibration. Gently depress the step-down part of the flange into the matrix just enough too barely cover it. Because they conceal the underside of the bowl, any color of matrix can be used for the backpour. When the first cast of matrix has gelled and cooled, the second cast (backpour) can be made. The permanent hats are available in a white or clear plastic, and with a choice of including an overflow, or no overflow. Gruber part numbers beginning with PH are permanent hats.
Fabricated of high-density polyethylene, a reusable hat will provide many trouble free castings if reasonable care is exercised in its use and storage. A reusable hat is applied to the mold after the initial pour of the matrix has been vibrated. It is placed over the bowl and the rim of the hat is gently pressed into the un-gelled matrix. A generous 2” flange is provided around the perimeter of the hat to allow for maximum adhesion of the hat to the matrix. Reusable hats are also available with an “untrimmed” flange around the perimeter.
To order a Reusable Hat, place the letters "RH" in front of the series designation of the bowl with which the hat will be used. For example: If ordering a Reusable Hat for a series "S" bowl, the order would read, "RH-S."
Reusable Funnels are a convenient add-on to your Reusable Hat. They are available in Round, oval and square to match your Reusable Hat
Which type of female "hat" is best for your needs - a Permanent Hat or a Reusable Hat?
Fiberglass Female Molds are the most dimensionally stable, and result in a uniform wall thickness. Reusable Polyethylene Female Hats are still preferred by some customers, even though they are more difficult to work with and produce a less uniform part. Permanent Female Hats are very popular because of their ease of use. We suggest that you try the different types of female hats and select the one(s) that best suit(s) your own needs and requirements.