How unique is the frame of a Deknudt Mirror?

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Mirror Manufactuirng

www.deknudtmirrors.com

Production of

PU frames

Technichal info about maximum dimensions :

Size of the mould : maximum 1900 x 1200 mm

Density PU frames : +- 400 gr/dm³

Density security gates :+- 600 gr/dm³

PU frames of high density (= more than 350 gr/dm³) have the same processing possibilities as wood.

Little series are perfectly possible due to the relatively low mould cost. (depending on the size and the difficulty about 3000 - 5000 EURO).

PU frames are water resistent, can handle high and low temperatures without any problem and do not change form < == > Wood (shrinkage, swelling, bowing… wood lives)

In house design team designs constantly new mirror models

From an approved drawinga prototype is sculptured.Generally by hand in wood.

With the prototype a mould is made in epoxy.Both front and backside.Cfr. Waffle iron

Opened mould irons

Cfr. Waffle irons

Step 1 : spraying loosener

(cfr. Greasing waffle iron) to prevent PU from sticking to the mould

Step 3 : Injection of the PU foamIs injected from one side of the mould.Once the foam is coming out on the other side,the hole of the mould is slammed shut

Step 2 : close mould with a clip systemThe mould irons are shut with a clip.The expansion pressure of the PU foam would openthe mould

Step 4 : let PU foam become hard

Depending on the design, about 15 to 20 minutesfor the PU foam to expand and harden.

During the expansion , exoterm reactions warms thePU to about 40 °C == > H2O cooling around the mould

Step 5 : Take the frame out of the mould andclean itRemove frame from mould.Clean mould for next round.

Step 6 : stripping

PU burrs are stripped from the frame,little holes are filled, frame is cleaned for primingQuality control.

Step 8 : Primer

Primer is sprayed on the frame.

Depending on the final decoration : ¤ in colour ¤ with glue for gold or silver leaf

Step 7 : Drying oven

PU frames are hung for at least 10 daysin an oven of about 40°C in order to drive out air and possible gasses.

Step 9 : gold or silver leaf

Frame is covered with leafs of metal in gold, silver or cupper colour by hand

Step 10 : Brushing off

Once covered, the frame is brushed to remove all the rest leafs and clean it up.

Step 11 : Final decoration

Depending on the desired decoration, the gold- or silverleafed frame is finished with sand or oil patinas.

Step 12 : After putting on a protecting varnish layer, the frames are thoroughly checked.

How unique is the frame of a Deknudt Mirror?

Design