Speakers: Dan OConnor Chris Porter

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BULK MOLDING COMPOUND/BMC INC.

• SpeakersDan OConnorChris Porter

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Agenda

• Overview of Bulk Molding Compound
• Overview of BMC, Inc.
• Video
• Processes Involved
• Advantages/Disadvantages of Processes
• Advantages of BMC Over Metals
• Advantages of BMC Over Thermoplastics
• Competitive Comparison
• Product Applications of BMC
• Future Applications of BMC
• Case Study BMC vs. Stainless Steel

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Overview

• Bulk Molding Compound (BMC) is a pre mixed fiber
  reinforced material that cures under heat and
  pressure
• It primarily consists of a thermosetting polymer,
  glass fiber reinforcement and a filler
• Cross-linked bonds between the chain molecules
  enhance the performance of BMC as opposed to
  other polymers

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Overview
Mixing components to create the BMC Compound
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• Bulk Molding Compounds, Incorporated (BMC) is a
  privately owned company founded in 1978. It is
  the largest manufacturer of bulk molding compound
  in the world.
• Manufacturing locations in
• North America
• South America
• Europe
• Asia

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Processes

• BMC can be shaped into parts by the following
  processes
• Compression Molding- Solid material is
  introduced into an open, heated cavity and
  compressed by heated plunger until the part is
  formed
• Transfer Molding- Solid material is introduced
  into a heated cavity and allowed to become
  molten, then a heated plunger forces the molten
  material into channels or runners which introduce
  the material into adjoining die cavities
• Injection Molding- Material is heated under
  pressure, injected into a mold through nozzles
  and allowed to harden

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Processes
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Processes
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Process Advantages/Disadvantages Compression
Molding

• Advantages
• Tool and machinery cost is lower than other
  processes
• High dimensional precision and surface finish
• Reduces or eliminates secondary processes

• Disadvantages
• Not good for thick wall sections because of large
  cure times
• Part complexity is low because flow of material
  is limited
• Not economical for large scale production

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Process Advantages/Disadvantages Transfer Molding

• Advantages
• Can produce relatively complex parts with thin
  sections
• Enables some of the advantages of injection
  molding to be used with thermosetting polymers
• Good tolerances and surface finish

• Disadvantages
• Can only produce small to medium sized parts
• Large loss of material in pot, well, sprue and
  runners which must be discarded

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Process Advantages/Disadvantages Injection
Molding

• Advantages
• Can produce complex parts
• Economical for large scale production
• Low cycle time
• Low scrap produced

• Disadvantages
• Not suitable for low scale production
• Higher tooling and mold costs

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Advantages Over Metals

• More design freedom through part consolidations
• Close tolerances often eliminate post molding
  operations
• Excellent corrosion resistance (e.g. chemical,
  water, humidity)
• No painting necessary due to mass coloring
• Excellent electrical insulation properties
• Good strength/stiffness weight performance
• Outstanding sound dampening properties
• Low thermal conductivity
• Lower project cost
• Lower tooling cost
• Faster time to market

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Advantages Over Thermoplastics

• Dimensional Accuracy
• Dimensional Stability (creep resistance) over
  broad temp. range
• Good property retention over long term (aging)
• Low thermal linear expansion (same as steel)
• High mechanical properties (e.g. strength,
  stiffness, impact)
• Excellent electrical properties
• Inserts can be used in the molding process
• Corrosion resistance in aggressive environments
• Can be mass colored to specification
• Lower mold cavity pressure
• Faster cycle time

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Competitive Comparison
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Competitive Comparison

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Competitive Comparison
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Competitive Comparison
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Product Applications of BMC

• BMC can be used in many products
• Granite-X is stain resistant with high strength,
  while appearing similar to stone.
• Conductive BMC is electrically conductive and
  offers creep and corrosion resistance, all at a
  lower cost than metals. This also has potential
  in emerging fuel cell markets.
• BMC 300 is applicable to many bathroom needs,
  with corrosion and stain resistance, including
  toilet seats and sink basins.

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Product Applications of BMC

• BMC 100, 200, and 400 are suitable for many
  electrical applications with very high electrical
  resistance, heat resistance, and dielectric
  properties this makes it useful for circuit
  breakers and motor brush holders.
• BMC 1050s Indoor and outdoor lighting
  applications can be met by thermal stability, up
  to 350 degrees Fahrenheit.
• Automotive applications of BMC compounds include
  valve covers and headlight reflectors due to
  their heat resistance, dimensional stability,
  weight reduction, and lower tooling cost.

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Product Applications of BMC
BMC has been used for headlamp reflectors since
the mid 1980s. The main advantage here is the
compatibility with coatings and adhesives. This
use of BMC has been approved by GM, Ford, and
Daimler Chrysler for use in fog lamps.
The stain resistance and high gloss of BMC 310
makes it ideal for use as a refrigerator door
handle
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Product Applications of BMC
NOT BMC
-Nylon intake manifold of the 4.6 Ford Crown
Victoria. -Contains stress crack because of hot
environment around engine. -Reimbursing
individuals may cost Ford 375 million
-Of the 60 million BMC valve covers in use today
there have been no material-related failures
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Product Applications of BMC

• BMC 880 can be used to imitate clay tile for
  roofing.
• Lightweight and highly durable will not corrode,
  split or warp.
• Successfully passed tests for high winds, driven
  rain infiltration, flammability, water
  absorption, and weathering.

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Future Applications of BMC

• Fuel Cell Plates- PEM fuel cells contain bipolar
  plates that must be rigid enough to support the
  membrane without any leaks of liquids or gas and
  maintain their dimensions without any creep. This
  can be at temperatures generally around 80C but
  can reach temperatures up to 120C. The material
  must also be a good conductor of electricity and
  have a long service life. Low cost and high
  performance are two advantages of BMC in this
  application.
• BMC for Noise Absorption- Developments are
  underway to double the noise dampening properties
  of BMC. This would give significant benefits over
  metals for applications such as housings and
  components for electrical motors and gearboxes,
  as well as engine components.

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Case Study
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Questions