Epoxy Course

Lesson 1 • What Epoxy Resin Actually Is

Defines epoxy resins at the molecular level and distinguishes them from other polymer systems. Establishes the chemical baseline for all subsequent mixing and curing concepts.

Lesson 2 • Additives, Fillers, and Modifiers

Surveys pigments, flexibilizers, reactive diluents, and fillers that alter epoxy performance. Prepares students to formulate systems for specific application requirements.

Lesson 3 • Hardeners and Curing Agents

Explains amine, anhydride, and polyamide hardeners and their distinct cure profiles. Connects hardener selection to final mechanical and thermal properties.

Lesson 4 • The Curing Reaction Explained

Traces the crosslinking reaction from liquid mix to solid thermoset. Students connect exothermic heat generation to practical mixing volume limits.

Lesson 1 • Substrate Compatibility Assessment

Evaluates adhesion potential of wood, metal, concrete, foam, and plastics before application. Links surface energy and porosity to bond strength outcomes.

Lesson 2 • Hardener Pairing and Ratio Accuracy

Demonstrates how off-ratio mixing causes tacky, brittle, or under-cured results. Students calculate correct ratios by weight and volume for multiple systems.

Lesson 3 • Sourcing, Storage, and Shelf Life

Covers supplier evaluation, proper storage conditions, and shelf-life monitoring for epoxy components. Prevents degraded material from entering production.

Lesson 4 • Reading Technical Data Sheets

Decodes viscosity, gel time, Shore hardness, and Tg values from manufacturer data sheets. Enables informed comparison of competing products before purchase.

Lesson 1 • Chemical Cleaning and Degreasing

Applies solvent wiping, acid etching, and alkaline cleaning to remove oils, oxides, and release agents. Connects cleaner selection to substrate material compatibility.

Lesson 2 • Priming and Tie-Coat Application

Demonstrates penetrating primers and tie coats that bridge substrate and topcoat chemically. Ensures compatibility between prep work and the epoxy system applied.

Lesson 3 • Why Surface Prep Determines Bond Strength

Explains how contamination, oxidation, and surface profile affect adhesion at the molecular level. Motivates rigorous prep as the single highest-impact variable.

Lesson 4 • Mechanical Preparation Methods

Covers sanding, grinding, abrasive blasting, and scarifying for creating mechanical anchor profiles. Students select grit, media, and tool type for each substrate.

Lesson 1 • Mechanical and Powered Mixing

Covers drill-mounted paddles, planetary mixers, and static mix nozzles for larger or more viscous batches. Balances mixing speed against air entrainment risk.

Lesson 2 • Measuring and Metering Systems

Compares manual weighing, graduated cups, and pump metering for accuracy and throughput. Students calibrate equipment and verify output ratios before production runs.

Lesson 3 • Manual Mixing Best Practices

Demonstrates scrape-and-fold technique, wall and bottom scraping, and transfer mixing to achieve homogeneous blends. Prevents streaks and unmixed hardener pockets.

Lesson 4 • Degassing Techniques

Applies vacuum chamber degassing and heat-assisted thinning to remove entrapped air before pour. Students set vacuum levels and timing for different resin viscosities.

Lesson 1 • Brush and Roller Application

Covers nap selection, roller speed, and back-rolling technique for coating flat and curved surfaces. Connects tool choice to film thickness and bubble release.

Lesson 2 • Squeegee and Trowel Application

Demonstrates notched squeegee and trowel use for self-leveling and mortar-body epoxy systems. Students control spread rate and thickness on horizontal surfaces.

Lesson 3 • Film Thickness Control and Verification

Uses wet film gauges and dry film thickness meters to verify coverage meets specification. Connects under- and over-application to performance and cost consequences.

Lesson 4 • Casting and Pouring Techniques

Guides deep-pour and thin-pour casting into molds, managing exotherm and layer sequencing. Students calculate maximum safe pour depth per resin system.

Lesson 1 • Rework, Repair, and Recoating

Covers sanding, solvent washing, and recoat window management for repairing defective epoxy layers. Students restore adhesion between coats without full removal.

Lesson 2 • Ambient Cure Conditions and Monitoring

Defines acceptable temperature and humidity windows for ambient cure and methods to monitor them. Prevents under-cure caused by cold, damp, or contaminated environments.

Lesson 3 • Common Defects and Root Causes

Catalogs fish eyes, amine blush, pinholes, cratering, and delamination with their root causes. Enables rapid diagnosis before defects propagate or require full rework.

Lesson 4 • Elevated Temperature Post-Cure

Explains how post-cure ovens and heat lamps raise Tg and chemical resistance beyond ambient cure limits. Students design ramp-and-hold schedules for specific resin systems.

Lesson 1 • Marine and Waterproofing Applications

Applies epoxy barrier coats, fairing compounds, and underwater repair systems to marine substrates. Addresses osmotic blister prevention and wet-surface adhesion challenges.

Lesson 2 • Decorative and Art Epoxy Techniques

Explores resin art, river tables, geode effects, and metallic pigment pours using casting resins. Students control color blending, cell formation, and surface leveling.

Lesson 3 • Epoxy Flooring Systems

Covers primer, body coat, broadcast, and topcoat sequences for industrial and decorative floor systems. Students specify system build thickness for traffic and chemical exposure levels.

Lesson 4 • Structural Bonding and Potting

Uses filled epoxy adhesives and potting compounds for load-bearing joints and electronic encapsulation. Students select filler type and mix consistency for joint geometry.

Lesson 1 • Cost Optimization and Sustainability

Evaluates bio-based resins, recycled fillers, and solvent-free formulations against performance and cost targets. Students calculate total system cost including waste and rework.

Lesson 2 • Custom Formulation Principles

Applies stoichiometric calculation, equivalent weight theory, and blend ratios to design epoxy formulations. Students balance flexibility, hardness, and chemical resistance in a single system.

Lesson 3 • Systematic Failure Analysis

Applies root-cause analysis frameworks—fishbone, 5-Why, and fault tree—to complex epoxy failures. Students trace field failures back to formulation, process, or environmental causes.

Lesson 4 • Mechanical and Thermal Testing

Applies tensile, flexural, impact, and thermal testing to validate formulation performance against specifications. Students interpret test reports and identify formulation weaknesses.