Advancing mold release technology for aerospace composites manufacturing

Source (All Images) | Chem-Trend 

The aerospace industry relies on precise, highly controlled manufacturing processes to produce composite structures that meet strict performance, safety and certification standards. One area undergoing significant reevaluation is mold release technology.

Traditional solvent‑based mold release systems, most of which contain silicone, pose multiple challenges for aerospace manufacturers, affecting everything from part quality to environmental compliance.

The challenge with conventional mold release agents

Most solvent‑based mold release agents used today incorporate silicone to enable part release. However, silicone readily transfers onto composite surfaces during molding. This transfer creates substantial downstream complications: silicone contamination interferes with painting and secondary bonding operations, forcing manufacturers to perform extensive surface preparation before these processes can begin. Silicone residue also disrupts water break testing, a critical quality control method used widely in the aerospace sector.

Compounding this issue is the discrepancy between how traditional solvent-based releases are intended to be used versus how they are typically applied. While these products are formulated to provide multiple releases per application, in practice, most manufacturers reapply after every part. Over time, this leads to heavy release buildup on molds, increasing the likelihood of transfer and requiring aggressive cleaning to restore surface condition. These cleaning cycles consume labor hours, reduce uptime and accelerate mold wear, all while exposing operators to solvent-based volatile organic compounds (VOCs) and, in some cases, hazardous components.

A modern water-based approach

To address these longstanding challenges, Chem-Trend (Howell, Mich., U.S.) developed Zyvax® 1070W, a next-generation mold release agent engineered specifically for advanced composite and aerospace applications.

It is water-based, silicone-free and PFAS-free, supporting the industry’s shift toward cleaner chemistries, reduced VOC emissions and more sustainable manufacturing processes. By eliminating solvents and hazardous additives, Zyvax® 1070W aligns with environmental stewardship goals while maintaining the high level of performance required in aerospace production.

Zyvax® 1070W is a water-based, silicone-free mold release agent designed to eliminate release curing time, which significantly reduces tool prep time. 

Zyvax® 1070W is designed to be applied after each molding cycle, matching the application pattern already used across much of the aerospace composites industry.

The product is also engineered for intentional transfer, meaning each molding operation deposits a controlled, predictable amount of release onto the part surface. This controlled transfer naturally limits the amount of material left behind on the tool, preventing the accumulation of heavy buildup that is common with traditional solvent-based systems. Between cycles, operators simply apply a light touch‑up coat to refresh the mold surface, enabling consistent release performance without excessive residue.

Because Zyvax® 1070W contains no silicone, any transferred material can be removed easily using common water-based or solvent cleaners. This greatly simplifies downstream preparation for painting, bonding or inspection, reducing labor time and supporting more reliable finishing operations. The application process itself is simple: Zyvax® 1070W requires no cure time. Once wiped or sprayed onto the mold and the water carrier flashes off, the surface is ready for composite layup.

Application techniques

Watch the proper ways to utilize Chem-Trend’s aerospace composites molding release agent, Zyvax® 1070W. 

Added benefits for aerospace manufacturing

A notable advantage of Zyvax® 1070W is its light tack, which helps stabilize prepregs and surface plies during layup. This reduces material movement during infusion, hand layup or automated placement operations and may eliminate the need for separate tackifiers.

The product is also part of a complete mold preparation system. Primers, offered in water-based formulations, enhance mold surface consistency by filling micro-porosity, addressing minor imperfections and compensating for areas of tool wear. This creates a hardened, tougher surface that improves part quality and promotes cleaner, more reliable release behavior.

Sealers, also available in water-based formulas, provide an additional protective layer between the primer and release agent, enhancing surface uniformity and boosting overall release performance across multiple molding cycles. Combined with the water-based Zyvax® 1070W release agent, these materials create a cohesive, high-performance mold treatment system tailored to demanding aerospace requirements.

Enhancing efficiency, quality and sustainability

The combination of water-based chemistry, silicone- and PFAS-free formulation, controlled transfer, simplified cleaning and improved mold preparation presents a modern solution to longstanding challenges in aerospace composites manufacturing. By reducing VOC exposure, minimizing mold buildup, extending tool life and supporting efficient downstream finishing operations, Zyvax® 1070W helps manufacturers achieve higher-quality parts with greater consistency, while contributing to a cleaner, more sustainable production environment.