Covering Materials
Most model aircraft today are covered with plastic film, whether they are built from a kit or purchased in almost ready to fly form. In general, film coverings are made from two or three layers - a clear layer on the outside which is made from polypropylene or polyester, a colour layer which gives the film its colour, and an adhesive layer, which is heat sensitive. In some cases, usually the lighter weight films, the adhesive has to be applied to the film before it is attached to the model, in others, the adhesive is combined with the colour layer, by using a coloured adhesive. These latter films will fuse colour into the wood, such that if an airframe is ever recovered, it will be stained from the previous colour. This isn't necessarily a problem unless the new covering scheme uses lighter colours, in which case, bleed through is likely.

The film is fixed to the model by ironing it onto the wooden framework with a warm iron; the heat sensitive adhesive bonds the film to the wood or other substrate. Both polypropylene and polyester films will become elastic at temperature. When heat is applied to a film and the film is tensioned, it will stretch, whereas when heat is applied and the film is not tensioned, it will shrink. This useful property allows the complex curves of an airframe to be covered using a combination of stretching and shrinking, producing a smooth, high gloss finish. Polypropylene films will become elastic at lower temperatures, and are more easily damaged by excessive heat, whereas polyester films can withstand higher temperatures and will shrink much more. Both types have their place, but it is easier to produce good results from polyester films.

Advantages of plastic films over other methods include:-

Advantages Disadvantages
  • Clean, odour free application
  • Material is self-coloured, eliminating painting
  • Complex shapes can be cut and applied, making highly decorative schemes possible
  • It can be difficult to achieve a wrinkle free finish
  • If models are subjected to high temperatures, such as a car interior on a sunny day, the covering can sag and wrinkle

There are many different brands of covering film, but they are usually variations of the above. Some of the more common materials are described below:-

Solarfilm

This is probably the most commonly used film in the UK today. It is a polypropylene film with a pigmented adhesive layer. Advantages are that it is cheap, available in a wide range of colours including fluorescents, and can be used direct onto polystyrene foams. Disadvantages are that it will not shrink as much as polyester, and it can be hard to produce a wrinkle free result. It is also susceptible to bubbling when one layer is applied over another, due to gas formed when the adhesive/pigment is heated.

Solartex

Rather than a smooth polyester film, Solartex is a woven polyester fabric, coated with a pigment. This makes it ideal for reproducing fabric covered aircraft, and is the covering of choice for models such as WW1 biplanes. It has very good shrinking properties, and is quite easy to apply. However, it suffers from bubbling when applying over another layer, and although it is fuel proof, it really needs a coat of clear fuel proofer to prevent dirt from becoming engrained in the fabric weave. Another disadvantage is weight.

Profilm

This film is a polyester, with separate colour and adhesive layers. This means that it can be repositioned when applying to the airframe without leaving coloured marks. The adhesive works at quite low temperatures, but because it is polyester, high temperatures can be used to shrink it. Profilm is easiest iron-on film to use, and excellent results can be achieved, but it is more expensive than most other coverings. It is made in Germany and sold under the brand names of Profilm, Oracover and Ultracote.

Monokote

This film is a polyester, with a single coloured adhesive layer. Although it is hard to find in the UK, it is the most popular film in the US, and many American ARTF models come covered in Monokote. In general, higher temperatures for application and shrinking are required compared with other films. The polyester layer is quite thick, making it durable, but at the expense of weight. I have used it a few times, and though it can gas and generate bubbles, this is less severe than the Solarfilm range.

Traditional Materials

Although plastic films are widely used, more traditional covering methods such as doped tissue, silk and nylon are still used, particularly for vintage models. These methods are generally more involved, and can be messy, they still have their adherents, and can give very durable, lightweight finishes when applied carefully.

Weight

One of the key consideration when choosing the covering method for a model is weight. A lightly built small aircraft will need a light covering if it is to fly successfully, and weight is a key consideration for electric aircraft. The table below lists the minimum and maximum weights in grammes per square metre for a wide range of covering materials, and I'm indebted to Michael Rolls from the RC Modelflying internet forum for the data. It is reproduced here with his permission. The variation in weights comes from different colours having different densities and the finishing method used. For example, silver Solartex is the heaviest of the range, and natural the lightest.

Covering Min gm/mē Max gm/mē Manufacturer
Polimicro 1.3 1.3 Indoor covering Indoor Model Supply
2micron clear mylar 2.2 2.2 WES Technik GmBH
2 micron aluminised mylar 2.6 2.6 WES Technik GmBH
.012 condenser paper 3.7 3.7 Indoor covering Indoor Model Supply
4micron aluminised mylar 6.8 6.8 WES Technik GmBH
5 micron clear mylar 7.0 7.0 WES Technik GmBH
5 micron Microlite 10.0 15.0 Risteen Assoc.
Lt. Silkspan 12.0 12.0 Sig
Jap tissue (Lite Flite) 12.0 12.0 Esaki
Litefilm/Solite 20.0 20.0 Solarfilm
Micafilm clear 22.0 22.0 Coverite
Airspan 24.0 26.0 Solarfilm
Polyspan 25.0 25.0 Klaus Salzer
Litespan 28.0 32.0 Solarfilm
Coverlite 28.0 28.0 Coverite
Micafilm colour 35.0 35.0 Coverite
Fibafilm 40.0 45.0 Solarfilm
Solarfilm 50.0 65.0 Solarfilm
Monokote transparent  57.0 57.0 Topflite
Solarspan 60.0 75.0 Solarfilm
Solarkote 65.0 75.0 Solarfilm
Solarcover 65.0 80.0 Solarfilm
Monokote solid 75.0 75.0 Topflite
Solartex 80.0 95.0 Solarfilm
Glosstex 120.0  130.0 Solarfilm

 

This page was last updated on 21/02/04

Copyright Jonathan Mead 2002