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High Quality hand laminating resins
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Resins are a class of versatile and highly viscous liquids that can transition into solid structures.
In the context of laminating, resins are combined with structural backing (reinforcement). Classic examples include glass fibre matting and carbon fibre fabric.
This is often referred to as the ‘reinforcement phase’, whilst the resin acts as the ‘matrix phase’.
Such combinations are referred to as composites, examples being fibreglass (GRP) and carbon fibre.
Resins typically bond well to a variety of surfaces, from timber decking to concrete, as well as existing fibreglass and carbon fibre composites.
Laminating resins compatible with a range of reinforcements.
These typically centre on epoxy (paired with carbon fibre, Kevlar® and certain glass fibre) and polyester-based resins (paired with glass fibre).
Resins are used in projects requiring a strong, often thin, seamless and durable layer or structure.
Resins are key to composite production. Classic composite examples include fibreglass and carbon fibre, both made using polyester and epoxy resin respectively. These are viable alternatives to structures like wood in that it does not rust, is lightweight and both water and chemically resistant. It is also preferable to steel given its capacity to be moulded and strong adhesiveness which replaces the need for welding and eliminates rust.
Resins are one of the core ingredients of several sectors, from renewables (e.g. wind turbines) to construction, aerospace and marine industries.
When a resin cures, the molecules within the structure cross-link, forming molecular bonds. These bonds render the resin a single, homogenous structure. This structure is seamless – making it an excellent waterproofing and chemical coating technology – and it is also able to disperse impact, a common feature of structural breakdown, across its entire structure.
Another benefit of resins is the high level of adhesion they provide between the substrate they are applied to and the resin-based composite itself. When fibreglass laminate is applied to wooden timber decking, for instance, it creates a layer that is almost at one with the timber, making it far superior versus thin, largely superficial linings like EPDM.
Generally, resins offer excellent abrasion and impact resistance, waterproofing, chemical resistance whilst also being very lightweight and very strong. These features can be more precisely tailored to individual applications depending on the resin type and reinforcement material used.
Epoxy resin, for instance, is suitable for structures requiring a high degree of strength, like bicycles, typically when combined with Kevlar. Polyester resin, on the other hand, is used to protect structures like flat roofs, benefitting from its lower cost and a higher degree of flexibility.
Q. What are laminating resins used for?
A. Laminating resins are combined with reinforcement materials like carbon fibre fabric and glass fibre. The combination of resin and a reinforcement phase yields a composite – namely carbon fibre and fibreglass. These composites are high-performance materials with a range of physical and mechanical properties.
Q. What resin should I use?
A. This is project-specific and dependent on several factors like cost, strength-to-weight ratio, chemical resistance, cost and thermal performance. Overall, the most popular resin based upon global consumption is polyester resin, marginally above epoxy resin and other resin types like polyurethane.
A comparison between epoxy and polyester resin highlights some of the key differences.
Q. What are the types of laminating resins?
A. Main resin types include, but are not limited to, epoxy, polyester and vinyl ester.
Q. How do I use resin?
A. Resin usage depends on the type of resin. Typically, a catalyst (hardener) should be used to facilitate curing, as is the case for polyester and epoxy resin.
Q. What is a laminate?
A. Laminate composites are made from successive layers of ply. The term ‘ply’ refers to a consolidated layer of resin-impregnated reinforcement (e.g. carbon fibre, aramid fibre or glass fibre).
The resin (matrix) holds each layer of fibre together and across layers. It has either a two-dimensional (ie, planar) orientation comprised of arrangements that are either orthotropic (referring to layers of orientated fibres) or randomly oriented layers of fibres.
Ply lay-up depends on the anticipated loading of the structure where the laminate will be used. The fatigue behaviour of laminates is highly dependent on the lay-up of the constituent plies.
The lamination process is intended to be a permanent modification to the resin and reinforcement and should invoke properties that cannot be achieved by each material independently.
Q. How do I choose a resin?
A. Generally, most resins used for laminating centre on epoxies, polyesters and vinyl esters. These can be summarised as follows:
+ Polyester is paired with glass fibre (chopped strand matting) to form fibreglass.
+ Epoxies are paired with carbon fibre and aramid fibre (Kevlar®). Some glass fibre types are also suitable; stitched or woven are fine, but if chopped matting is used it must be powder bound.
For repairs to existing laminate structures like fibreglass and carbon fibre, it is generally wise to repair the original structure with the same resin system that was originally used.
Note: It is important to check the compatibility of the resin with the reinforcement material.
Q. How do I choose a reinforcement fabric?
A. Factors affecting the choice of reinforcement centre on cost, resin compatibility, mechanical, chemical and physical properties as well as the skillset and tools required.
Prospective users should first consider the end product or part, what type of composite that is (e.g., is it fibreglass or carbon fibre?) and then work backwards based upon the resin system and compatible reinforcement type required.
Q. What types of laminating are there?
A. The majority of laminating methods centre on hand and spray lay-up.
Other types include more automated versions, which may incorporate injection moulding methods.
The type of laminating used also depends on the industry. Hot or cold laminating is commonly used in the electronics industry.
Q. What do I need to create a laminate?
A. In the context of laminate composites, such as carbon fibre and fibreglass, a matrix phase (resin) and a reinforcement phase (carbon fibre cloth or glass fibre matting) are required.
To initiate the curing process for the resin, a hardener/catalyst is also required to be pre-mixed, prior to laminating.
Appropriate tools are also needed. At a minimum these include bushes and rollers. More sophisticated equipment may centre on vacuum pumps and autoclaves.
Q. How do I calculate the amount of hardener to use?
A. Hardener concentration is specific to each resin type.
Polyester Resin
Polyester resin typically requires somewhere in the range of 1 – 4 % w/v, referring to the volume of catalyst (mL) to add to the unit weight of resin (kg).
For example, if aiming for 1 % catalyst, then add 1 mL of MEKP to every 1 kg of polyester resin. Conversely, if aiming for 2.5 % catalyst, add 2.5 mL of MEKP to 1 kg of resin.
Epoxy Resin
Epoxy resin may require different types, depending on the types used. Epoxy resin-hardener mixtures may be written as parts by weight, whereby 50 grams of hardener is added to 100 grams of epoxy resin in order to initiate curing.
In the Downloads section for each product, Resin Library provides recommended quantities of hardener (or catalyst) to add to each resin.
Note: when measuring resin and hardener, use accurate weighing or volumetric measuring equipment. It is vital that accurate concentrations are achieved to ensure effective curing.
Laminating resins are designed to present favourable ‘wetting out’ characteristics for glass fibre, carbon fibre and other reinforcement materials. Classic examples include polyester resin (used with glass fibre to produce fibreglass) as well as epoxy resin (used with carbon fibre fabric to produce carbon fibre composites).
When dealing with laminating resins, it is important to consider the compatibility of the resin with the reinforcement.
Resins themselves are generally not recommended for application unless specified. Polyester resin, for instance, is brittle and prone to fracture and its excellent properties are only observed when it is part of a composite. The same is largely true for epoxy resin, which provides exception performance in carbon fibre composites.
The benefits of polyester and epoxy resin are more fully realised when combined with a reinforcement material.
In general, polyester resin is combined with a glass fibre reinforcement. This is hardened (cured) through the presence of a small quantity of MEKP catalyst. The result is a fibreglass composite.
Note: polyester resins contain styrene that can dissolve polystyrene and polypropylene materials.
Epoxy resin can be combined with carbon fibre fabric and certain types of glass fibre reinforcement, such as stitched or woven versions – or powder-bound chopped strand matting.
Q. What does laminating involve?
A. Laminating involves the placement of multiple layers of reinforcement fabric (e.g. glass fibre or carbon fibre) onto a surface. The reinforcement may be infused with resin either before or after placement, depending on the process.
‘Prepeg’ is the name for reinforcement which has been pre-impregnated with resin (often epoxy) and is ready to lay onto the surface.
Q. What are Important laminate properties?
A. The performance of a laminate depends on the following properties:
+ Adhesive capacity to hold the fibres and respective layers together
+ Fibre type and therefore performance (e.g. tensile strength, elongation, etc.)
+ Fibre geometry angle per layer
+ Matrix (resin) to fibre (reinforcement) ratio
+ Resin cure temperature
+ Compression (pressure) extent and distribution during curing
+ Environmental conditions (e.g. humidity, contaminants, etc.)
Some of the most commonly used definitions are presented below.
Wetting out: refers to the process whereby fibrous material is impregnated with a resin the laminating. More specifically, it refers to its wettability, namely the propensity of the resin to spread on a surface. High reinforcement wettabilities are favourable for resins because it means the resin can easily infuse into the fibres and replace air pockets.
Lay-up: the process is a laminating process for composite materials whereby the final product is comprised of layers of resin-infused fibrous reinforcement (ply).
Open moulding: reinforcement is open to air whilst it is infused with resin and hardens. Uses different processes, including hand lay-up, spray-up, casting, and filament winding. It is favoured by low-volume or low/moderate-performance parts.
Closed-moulding: reinforcement is not exposed to air under resin infusing or hardening. This process is performed in a two-sided mould or inside a vacuum bag. It is typically automated and requires special equipment. It is favoured by high-volume or high-performance parts.
Hand lay-up: the most common and cheapest form of open-moulding. Fibrous reinforcements are placed by hand in a mould/surface and resin is applied with a brush or roller.
There are also a range of lectures and videos, outlined below, which act as excellent educational sources for users of laminating resins in the context of composites.
The following section outlines the types of laminating techniques used when working with resins. Keep in mind that while some methods are more accessible to beginners, mastering any lamination technique requires practice and attention to detail. The choice of lamination method depends on factors such as the desired properties, complexity of the part, production volume, and available equipment. Safety precautions should always be followed, and beginners may benefit from guidance or training when working with advanced methods.
– Involves applying resin directly to dry reinforcement materials, like glassfibre or carbon fibre, by hand.
– Requires careful manual placement and saturation of each layer.
– Typically used for small-scale or custom projects.
– Difficulty: 4/10
– Total Cost: low (basic materials and tools)
– Suitable for beginners willing to learn proper resin application techniques.
– Involves placing dry reinforcement materials on a mould, covering them with a vacuum bag, and sealing it.
– A vacuum is applied, which removes air and excess resin while compressing the layers.
– Produces high-quality, lightweight laminates with minimal resin waste.
– Difficulty: 5/10
– Total Cost: moderate (requires vacuum pump and bagging materials)
– Achievable for beginners with some guidance, as it involves more equipment and steps than wet layup.
– Uses pre-impregnated reinforcement materials (prepregs) that come with resin already applied.
– Layers are stacked, and the composite is cured under heat and pressure, often in an autoclave.
– Ensures precise resin content and is commonly used in aerospace and high-performance applications.
– Difficulty: 6/10
– Total Cost: moderate to high (prepreg materials and curing equipment)
– More complex due to the need for controlled curing conditions; beginners may require training.
– Involves placing dry reinforcement materials in a mould and covering them with a vacuum bag.
– Resin is then introduced into the mould under vacuum pressure, saturating the fibres.
– Allows for consistent resin distribution and is suitable for complex shapes.
– Difficulty: 7/10
– Total Cost: moderate to high (vacuum and infusion equipment)
– Requires a good understanding of resin flow and may be challenging for novices.
– Utilizes a two-part mould with dry reinforcement materials placed inside.
– Resin is injected into the closed mould under pressure, displacing air and saturating the fibres.
– Ideal for producing high-strength, low-weight composite parts.
– Difficulty: 8/10
– Total Cost: high (RTM-specific equipment)
– Complex process with specialised equipment, best suited for experienced individuals or professionals.
– Employed for cylindrical or tubular structures.
– Reinforcement fibres (e.g., carbon or fibreglass) are wound under tension with resin application.
– Precise control over fibre orientation and resin content.
– Difficulty: 7/10
– Total Cost: high (filament winding machinery)
– Involves technical knowledge and machinery operation, making it challenging for beginners.
– Continuous process where reinforcement fibres and resin are pulled through a heated die.
– Shapes are formed as the composite cures and solidifies.
– Suitable for producing profiles like rods, tubes, and structural components.
– Difficulty: 9/10
– Total Cost: very high (specialised pultrusion equipment)
– Extremely complex and typically reserved for advanced manufacturing due to specialised equipment and expertise required.
– Similar to wet layup, but a vacuum bag is used to remove excess air and aid resin saturation.
– Provides better control over resin distribution compared to traditional wet layup.
– Difficulty: 5/10
– Total Cost: moderate (basic materials plus vacuum equipment)
– Suitable for beginners with some experience in hand layup who want to improve the quality of their laminates.
Note: some of these videos are for general informational purposes only. Resin Library is not liable for any content or information presented.
+ Mechanical behaviour of glass and carbon fibre reinforced composites at varying strain rates and temperatures, 2014, C. Elanchezhian, B. Vijaya Ramnath, J. Hemalatha, 1405 – 1418.
+ Polyester resin for laminating
+ Synthesis and application of epoxy resins: A review, 2015, Fan-LongJin, Xiang Li, Soo-JinPark.
+ Multifunctionality in Epoxy Resins, 2019, Jaworski C. Capricho,Bronwyn Fox &Nishar Hameed
+ A Review on Polyurethane and its Polymer Composites, 2016, A. Atiqah, Mastura M.T.
When working with laminating resins, such as epoxy, polyester and others, prioritising health and safety is crucial to ensure a safe working environment for users, surrounding persons and environment. It is also a legal requirement.
Exposure to resins can cause serious health effects, including, but not limited to sensitisation, dermatitis and in extreme cases, death.
It is advisable to start by reviewing the Safety Data Sheets (SDS) provided in the Downloads tab for each product. SDS sheets are manufacturer-specific information and list potential hazards, safe handling practices, and proper disposal methods.
When laminating, ensure proper ventilation in the workspace to prevent the buildup of harmful vapours. If ventilation is insufficient, consider using local exhaust systems or wearing a respirator with appropriate cartridges. Personal Protective Equipment (PPE) is essential: wear chemical-resistant gloves, safety goggles, and a overall to protect skin and eyes.
Work in a well-lit area with good visibility and ensure that no open flames or ignition sources are nearby. Use appropriate tools for mixing and application. Carefully follow the manufacturer’s recommended mixing ratios to ensure proper curing and optimal material properties.
In case of skin contact, wash the affected area with plenty of water and soap immediately. If resin gets into the eyes, flush with water for at least 15 minutes and seek medical attention. Always have an emergency eyewash station and a safety shower nearby. Properly dispose of waste materials, including used brushes, containers, and excess resin, following local regulations and guidelines.
By adhering to these recommendations and maintaining a strong commitment to safety, associated risks can be minimised.
Note: this content is for general informational purposes only. Resin Library is not liable for any outcomes. Users accept full responsibility when purchasing these resins.
As outlined in one review, professional laminating settings see the final quality and performance of the cured composite depends on the factors used and each of them may be treated as the design variable in the optimisation problems.
Generally, they may be classified in the following manner:
Resin Mixture
Injection Moulding
In the context of injection moulding, the factors affect performance:
