Polyclast

Strata

Strata Polyclast combines bold, layered colors accented with white and gray fragments. Perfect for full handles or part of your own segmented builds.

Pebble

The Pebble Polyclast focuses on a unified color palette. Each piece features carefully selected multi-tonal variations that create visual depth and character. Great on it's own or as part of a themed segmented set.

Key Features

  •  100% Solid Urethane Matrix 

    Every block and scale is cast under high pressure using professional-grade, slow-curing urethane resin. This yields a void-free, monolithic material with an 80 Shore D hardness and balanced tensile strength.

  •  Predictable & Machinable 

    Polyclast cuts, drills, taps, and shapes like dense hardwood or synthetic micarta. It won’t fracture unexpectedly under fasteners or along hidden cleavage planes.

  •  Closed-Loop Sourcing 

    We incorporate our own pulverized, cured composite fragments and production dust back into new batches. This closed-loop process creates organic, irregular mineral textures that cannot be replicated through simple liquid pours.

 Machining & Grinding Instructions 

Polyclast behaves similarly to dense micarta or stabilized hardwoods. It creates a fine, powdery swarf rather than long melting strands or brittle shards.

Shaping & Profiling (Belt Grinder)

  • Rough Shaping: 80 to 120 grit (Ceramic or Zirconia). Cuts rapidly and leaves a clean silhouette.Refining Contours: 220 to 400 grit (Aluminum Oxide or Structured Abrasive belts).
  • Speed & Pressure: Run grinder at medium to medium-high speed with moderate, continuous pressure. Do not dwell in one spot to prevent localized heat buildup.
  • Wet vs. Dry: Works cleanly dry. If using a misting system or dip bucket, water will not swell or degrade the composite.

Drilling & Pinning

  • Drill Bits: Standard High-Speed Steel (HSS) or cobalt jobber bits. Brad-point bits produce exceptionally crisp entries.
  • Drilling Speed: Moderate spindle speed (~800–1,200 RPM).
  • Technique:Back the scale securely with a sacrificial wood block to ensure zero breakout on the exit hole.Clear chips frequently on deep holes.Counter-bore or chamfer pinholes lightly before driving mechanical fasteners.

Fasteners & Adhesives

  • Glue Compatibility: Accepts standard two-part epoxies (G/flex 650, West System, standard 30-minute epoxy) and cyanoacrylate (CA).
  • Bonding Prep: Scuff the bonding face with 60 to 80 grit paper to create mechanical tooth; wipe down with isopropyl alcohol (avoid harsh acetone soaks).

Finishing & Polishing Progression

Polyclast accepts finishes ranging from a grippy satin carry texture to a high-gloss, stone-like polish:

  1. Hand Sanding: Hand-block sand through 320 → 400 → 600 → 800 grit using wet/dry paper.For a durable, tactical/matte grip: Stop at 400–600 grit and buff lightly with a dry Scotch-Brite pad.
  2. Buffing (Wheel Polish):Use a clean, loose-muslin wheel running at 1,200–1,800 RPM.Apply light passes with White Diamond or Matchless pink compound.Finish with an untreated, dry muslin wheel for a deep, dimensional luster that exposes the internal strata matrix.
  3. Topcoats / Sealers: None required. Polyclast is non-porous and naturally waterproof throughout the entire piece. Do not apply hardening oils (Danish oil, Tru-Oil) as they cannot penetrate the surface.

Safety & Handling

  • Respiratory Protection: Always wear an N95 or P100 respirator when grinding, sanding, or sawing composite resin dust.
  • Dust Collection: Use standard extraction at the tool rest.