Epoxy matrix composites from waste for manufacturing tools for energy efficient moulding process

In this research, the viability of adding value to grinding steel swarf (GSS) and sheet moulding compound (SMC) residues through its use in the manufacture of hot-press compression moulds is investigated. The moulds serve for small batch production runs of SMC where cost, easy demoulding of parts and energy consumption are three central issues to resolve. The recovery of steel and SMC waste and its use as a filler in replacement of commercial aluminium and CaCO₃ powder, to reduce mould manufacturing costs, forms part of the proposed method. It is also an innovative development that may encourage other methods of waste recovery. The epoxy resin filled with 40 wt% GSS is 8.5% harder and 29.5% cheaper than the epoxy filled with aluminium. In addition, the thermal conductivity and density of the epoxy resin filled with 40 wt% SMC were 30.1% and 9.0%, respectively, lower than its counterpart in CaCO₃, which meant that the raw material costs of a 4 m³ mould manufactured with these novel polymer matrix composites registered a cost saving of € 14,028. Furthermore, the results of the moulding experiments confirmed that the hot-press compression mould manufactured with epoxy filled with 40 wt% GSS and SMC was able to manufacture a small batch of parts with no demoulding issues and its innovative thermal barrier provides a saving of 27% in energy consumption.