Silicon-based release coatings for molding applications

Overview

This solution is a silicon-based release coating system designed for molding applications. Built on a photo-driven tri-cure chemistry combining thiol-ene, epoxy-amine, and sol-gel mechanisms, the coating delivers strong adhesion to mold substrates over repeated cycling while enabling tunable surface properties. By adjusting the R-groups on the alkoxysilane reactants, surface polarity can be tuned from hydrophobic to hydrophilic, with contact angles ranging from approximately 60 to 110 degrees. This tunability allows manufacturers to match coating surface energy to specific polymer chemistries, supporting effective release across a range of molding processes. The technology is positioned as a non-toxic alternative to Teflon and similar fluoropolymer release agents.

Technical specifications

• Tri-cure chemistry: Photoactivated system combining thiol-ene, epoxy-amine, and sol-gel curing pathways for robust crosslinked networks
• Alkoxysilane base materials: Enable durable adhesion to diverse substrates including glass, stone, brick, wood, and steel
• Tunable surface energy: Contact angles adjustable from ~60° to ~110° via R-group modifications on alkoxysilane reactants
• Hydrophobic tuning: Incorporation of long-chain alkyls or lipid-attached surfactants for lubricating, low-surface-energy layers
• Hydrophilic tuning: Functionalization with amphiphilic, FDA-friendly additives such as amino acids (e.g., cysteine) for polar polymer release
• Thermal stability: Stable at temperatures well above 400°F
• Environmental durability: Demonstrated long-term stability exceeding one year in direct exposure
• Mar and scratch resistance: Good mechanical durability suitable for repeated molding cycles
• Application methods: Spray, dip, and wipe-on coating demonstrated on steel substrates
• Cure time: Full cure to usability within 24 hours; initial cure in 5–30 minutes

Technology readiness level

The coating system has been validated as a long-term stable protective coating on multiple substrates, including steel, with demonstrated spray, dip, and wipe-on application methods and full cure within 24 hours. Thermal stability above 400°F and over one year of environmental durability have been confirmed. The technology has not yet been tested specifically as a mold release agent, but the demonstrated adhesion, mechanical durability, and tunable surface properties provide a strong foundation for adaptation. Future validation will focus on tuning surface properties to minimize interactions with specific polymer structures (polyester, polyamide), followed by testing for longevity, reuse, and polymer compatibility under molding conditions.