Polyester for beginners

Polyester lamineerhars

Polyester is a synthetic resin that hardens after adding a hardener. This process is irreversible, so polyester cannot be melted. Polyester does not rot or rust and can be processed with a minimum of tools. With a polyester repair kit, you can easily carry out minor repairs. For example, on caravans, boats or swimming pools.

Polyester is usually combined with fibreglass, to obtain a strong, impact-resistant and rigid product. Examples of polyester products include boats, ponds, swimming pools, car bumpers, gutters, works of art, scooter covers, waterproof coverings and much more.

 

Benefits of polyester:

 

  • Polyester does not rot or rust.
  • Cheap and easy method to manufacture plastic or to do repairs.
  • Suitable for a huge number of applications.
  • Polyester is a strong and rigid system.

Combining polyester resin with glass fibre is called laminating. The resulting plastic is called a laminate, named after the different layers of fibreglass it is made up of.

Polyester is ideal for products where freedom of shape is paramount. Polyester with glass fibre is always laminated against a mould (temporary or otherwise). This temporary mould can be made of any material and can also become part of the construction. Examples of moulds are: polyester moulds, moulds made of wood, foam or plaster, stretched T-shirt fabric or chicken wire. You can make products in a mould, but also clad objects. In short, if you need something to laminate the polyester against, it can be made with polyester.

Polyester products can be finished in various ways. Against a smooth mould, gelcoat can be used, an approximately 0.3 mm thick thoroughly coloured layer based on polyester. This layer takes on the surface texture of the mould. A mirror-smooth finish is usually aimed for. For filling small holes and a tight finish, please use polyester putty. This product has a fast cure and is easy to sand.

  Application Features
RESION Polyester laminating resin
  • Coating with glass mat
  • Making adhesives and fillets
  • Polyester repairs
  • Impact-resistant
  • Fast curing
  • Easy to process
  • Economical
  • Stick-free curing
  • Low styrene emission
RESION Polyester casting resin
  • Casting of ornaments
  • Casting organic materials (flowers, insects)
  • Casting figurines
  • Jewellery
  • Fast-curing
  • Highly transparent
  • May show shrinkage (approx. 5%)
  • Reactivity adjustable
  • UV-resistant
RESION Vinylester resin
  • Mould making
  • Non-shrink coatings
  • Chemically resistant floors, horse trailers, cattle transport, walls, etc.
  • Feed troughs
  • High temperature resistance
  • Very high chemical resistance
  • Stronger than polyester
  • Fast curing
  • Osmosis resistant
RESION Polyester topcoat
  • Finishing of polyester ponds, swimming pools
  • Finishing of glass fibre laminate
  • Repair of gelcoat damage
  • Fast curing
  • Easy processing
  • High layer thickness
  • Thixotropic
  • Stick-free curing
  • Good water resistance
RESION Polyester gelcoat
  • Finishing polyester ponds, swimming pools (1st layer)
  • Colour coating in moulds
  • Fast curing
  • Easy processing
  • High layer thickness
  • Thixotropic
  • Good water resistance
RESION moulding gelcoat
  • Surface layer for durable moulds
  • High temperature resistance
  • High scratch resistance
  • High gloss level
  • Low porosity
RESION moulding resin
  • Construction material for durable moulds
  • Shrink-free curing
  • Suitable for high-speed lamination
  • Stick-free curing
  • 5 mm thickness wet-on-wet lamination
RESION abrasive gelcoat 
  • Bodywork repairs to polyester parts
  • For repaintable polyester products
  • Easy to sand
  • Very good adhesion with various paint systems
  • Thixotropic
  • High layer thickness
  • Easy processing
Polyester putty
  • Fine finishing of polyester laminates
  • Repair of scratch damage
  • Filling of metal parts (bodywork)
  • Filling of bumpers
  • Fast curing
  • Good sandability
  • Good adhesion to various substrates
  • Not water-resistant (use Epoxy putty under water)
Polyester fibreglass putty
  • Plugging of holes
  • Repairing cracks
  • Stronger than polyester putty
  • Fast curing
  • Tear resistant
  • Good adhesion to various substrates
  • Not water-resistant (use Epoxy putty under water)

On the other side of the polyester product, or if an object is coated, a polyester topcoat can be used. This layer is also a ca. 0.3 mm thick through and through coloured layer, but the surface structure depends mainly on the application technique (brush, roller or even spray) and will always be silky gloss and have some structure. It is possible to sand and/or polish this topcoat finish completely smooth.

Projects with polyester

There are several applications for polyester. For some applications, we have written a manual:

TIP: have something in mind but would like some advice first? Then contact our customer service. Our staff all have experience with polyester and can advise you on your project.

Reinforcement fibres

With polyester resin, we usually use a glass mat. This is a mat made of fibres about 5 cm long that are criss-crossed. These glass fibres are held together by an adhesive that dissolves in polyester resin. By spreading polyester resin on the mat, the mat will become flexible and take the underlying shape. So once the resin cures, we have a product that gets its strength from the glass fibre and stays in its shape because of the resin.

  Application Features
Fibreglass chopped strand mat 225gr/m2
  • Suitable as first layer behind gelcoat
  • Suitable as first layer for over polystyrene-free polyester
  • Suitable as final layer for finer finishing of fibreglass laminate
  • Thickness approx. 0.5 mm
  • Resin consumption 500gr/m2
  • Fine texture
Fibreglass chopped strand mat 300gr/m2
  • Suitable for polyester repairs
  • Suitable for covering wood (2x 300gr/m2)
  • Thickness approx. 0.7 mm
  • Resin consumption 700gr/m2
Fibreglass chopped strand mat 450gr/m2
  • Universal use
  • For rapid build-up of layer and thickness
  • Suitable for mould making
  • Thickness approx. 1 mm
  • Resin consumption 1000gr/m2
  • Economical
Glass fleece 30gr/m2
  • Suitable as first layer behind gelcoat
  • Suitable as first layer in mould construction
  • Suitable as final layer for fine finishing of glass fibre laminate
  • Thickness approx. 0.1 mm
  • Resin consumption 100gr/m2
  • High chemical resistance
  • Prevents print-through in gelcoat
Woven roving 300gr/m2
  • Suitable for extra-strong laminate in alternation with fibreglass mat
  • Alternate woven roving with fibreglass chopped strand mat 300gr/m2
  • Increases impact resistance
  • Thickness approx. 0.5 mm
  • Resin consumption approx. 500gr/m2
Woven roving 600gr/m2
  • Suitable for extra-strong laminate in alternation with fibreglass mat
  • Alternate woven roving with fibreglass chopped strand mat 450gr/m2
  • Increases impact resistance
  • Thickness approx. 1 mm
  • Resin consumption approx. 1000gr/m2
Spherecore 2 mm
  • For extra rigid polyester laminates
  • For lighter polyester laminates
  • Suitable for laminating round shapes
  • Increases stiffness
  • Faster build-up of thickness
  • Thickness approx. 2 mm
  • Resin consumption approx. 1200gr/m2
Spherecore 3 mm
  • For extra rigid polyester laminates
  • For lighter polyester laminates
  • Suitable for laminating round shapes
  • Increases stiffness
  • Faster build-up of thickness
  • Thickness approx. 3 mm
  • Resin consumption approx. 1800gr/m2
Spherecore 4 mm
  • For extra rigid polyester laminates
  • For lighter polyester laminates
  • Suitable for laminating round shapes
  • Increases stiffness
  • Faster build-up of thickness
  • Thickness approx. 4 mm
  • Resin consumption approx. 2400gr/m2

How do you make polyester resin?

Never prepare more polyester resin than you can process in 10 minutes. Approximately 2% hardener is added to polyester resin.

  • Don't mix too much polyester resin.
  • For small quantities (< 5 ml) of hardener, use a pipette.
  • For larger quantities of hardener, use a special MEKP dispenser.
  • Determine the amount of hardener according to the ambient temperature.
  • Mix resin and hardener carefully and scrape bottom and sides of the mixing cup.

How much polyester hardener do you need for polyester laminating resin?

The chart below shows how much hardener you need for polyester laminating resin.

  Hardener
  12-17 ℃ 18-23 ℃ 23-30 ℃
Resin: 2.5% 2% 1.5%
100 grams 2.5 ml 2 ml 1.5 ml
250 grams 6.25 ml 5 ml 3.75 ml
500 grams 12.5 ml 10 ml 7.5 ml
1000 grams 25 ml 20 ml 15 ml

How much polyester hardener do you need for polyester laminating resin?

The chart below shows how much hardener you need for polyester laminating resin.

  MEKP Potlife Full cure
Thickness 1 cm 1% 25 min. 10 hours
  1.5% 22 min. 3 hours
  2% 20 min. 2.5 hours
Thickness 3 cm 0.4% 40 min. 2 hours
  0.7% 27 min. 1.5 hours
  1% 25 min. 45 min.
Thickness 6 cm 0.3% 48 min. 45 min.
  0.35% 43 min. 30 min.
  0.4% 40 min. 30 min.

Laminating

Lamination is the technique/process of manufacturing a material in multiple layers (so that the composite material achieves improved strength) using a reinforcing material such as glass mat and polyester laminating resin. The reinforcing material is "wetted" with the polyester resin by using a brush or roller.    

Commonly used auxiliary materials when laminating:

TIP: we also have complete packages with all the auxiliary materials you use a lot when laminating.

Finishing polyester with polyester topcoat

After laminating, the laminate may be a bit rough. To finish the laminate and increase its weather resistance, you can coat it with a polyester topcoat. Lightly sand the laminate with 60-grit sandpaper to prepare it for the topcoat.

In the video above, Kees shows how to finish polyester with polyester topcoat. After curing, your product is protected from the weather and has the colour you want.

Polyester repair kit

Buy your polyester repair kit at Polyestershoppen.com. Our set is fully equipped with all the tools needed to carry out various repairs. Everything in one set! Easily repair holes, cracks and fractures in polyester items. Besides a small repair kit, we also have a polyester repair kit for the somewhat larger projects. Here, for example, we have laminating kit.

Personal protection

Dampmasker

Styrene fumes from polyester is harmful to health and the environment. Ventilate the area you will be working in well and preferably wear a half mask, especially in a small space. Also make sure to avoid skin contact with polyester resin and hardener by wearing suitable gloves, such as latex glovesnitril gloves or household gloves.  

Other commonly used protective materials:

TIP: Polyestershoppen has a complete package with all the protective materials you need while working with polyester.

Conclusion on working with polyester

As you have read in the article above, working with polyester is not enormously difficult. On this page, we have explained as best we can how polyester is processed, what the possibilities are and what to look out for during processing. There are many possibilities when working with polyester. Whether you make swimming pools, shower cabins, car parts, furniture or works of art, polyester can be used almost everywhere. The possibilities are virtually endless. After reading this article, do you still have questions or need advice for your project? Feel free to contact our specialists! They are happy to help you.

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Products used in this article

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Do it yourself jobs with epoxy (DIY), polyester and PU foam!

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