AEGIS commercializes PREP-3 resin evacuation technology. 

Click here to download the PREP-3 Process Flier

Click here to download the PREP-3 Process Bulletin

What is PREP-3?  PREP-3 is Preferred Resin Evacuation Process, AEGIS' 3-stage resin evacuation technique.

Gas assist processing has a long history of using various methods for evacuating resin from a gas molded part, frequently called gas assist spillovers or gas assist overflows. For too many years, the generic process of displacing resin from the molded part with gas injection was fraught with claim's or intellectual property, real and imagined.  Yes, there are patented methods - some are expired, a few are in effect and functional, but complex and not as practical to implement nor as repeatable as PREP-3. A couple of the techniques are just very bad ideas.

Why use resin evacuation?

Resin evacuation in the gas assist molding process is almost always implemented to achieve a Class A surface on a molding with a reinforced resin.  Glass filled resins in high gloss moldings are the most problematic, with high levels of mineral or talc also being problematic.  The low pressure gas assist molding process does not exert enough pressure on the cavity surface to "bury" the glass away from the cavity surface as can be achieved with conventional molding.   With PREP-3, we have achieved high gloss surfaces with 50% glass filler in dark colored resins.  Resin evacuation is also used to eliminate a "slug" of resin at the end of a flow channel that cannot be prevented with gas or resin processing controls, but this is much less common.

If you are molding a large cross section product (or designing a gas molded product or gas assist mold) that requires glass or other reinforcing fillers, a resin evacuation method should be employed, and PREP-3 is the most repeatable and cost effective method in the marketplace.

Is PREP-3 new?

PREP-3 has been implemented in products such as range handles (high temp, reinforced resins), automotive interior grip handles and other large cross section moldings that require the highest level of surface quality.  We are now commercializing the process to the broader general marketplace.

Why is PREP-3 superior?

Earlier processes involved methods that resulted in inconsistent results such as short shooting the cavity or open evacuation paths, or which required injecting gas into the resin melt once the cavity is short shot or completely filled, but with no evacuation path upon gas injection.  The PREP-3 process eliminates both of these problematic methods.

Aren't there other 3-stage gas assist resin evacuation processes?

Yes, but none are as effective and offer as wide a manufacturing window as AEGIS' PREP-3 method.

OK, now the bad news. How much is the PREP-3 license?

AEGIS does not license the PREP-3 gas assist molding method.  Our intent is to proliferate the methodology to enable our customers to 1) achieve superior results, 2) gas mold with a wider processing window, and 3) open the gas assist molding industry to options beyond the constraints imposed

for too long by expensive and often questionable licensing.

How do I learn more about PREP-3 for my gas molded applications?

AEGIS and it's affiliated companies can review your current or planned gas assist molding programs to determine whether PREP-3 resin evacuation is needed or will improve you gas molding program.  This review is free.  Our services beyond a basic review include:

•  Technology training at your facility for product and tool implementation of PREP-3

•  Product and tool design support for new or conversion programs, including the PREP-3 resin evacuation technique.

•  Basic PREP-3 design and implementation manual with specific guidelines for part and tool implementation (PREP-3 manual in development at this time)

AEGIS and its affiliated companies are dedicated to supporting your implementation of the advantageous gas assist molding process, from basic applications through resin evacuation via the PREP-3 method, multi-cavity tooling development, and turnkey product and tool design support.  Our gas assist control systems and accessories are unsurpassed in design, durability, and cost effectiveness.

Call AEGIS Consultants for more information! Phone: 757-271-9927

Click here to see our gas assist controller options, and the industry's only line of money saving recertified process controllers in the industry.