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					BULK MOLDING COMPOUND/
        BMC INC.


          Speakers:

        Dan O’Connor
         Chris Porter
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
   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
Mixing components to create the BMC Compound
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
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
     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
    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
    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
   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
   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
    Material            Common           $/lb     Specific   Modulus
                     Trade Name(s)       (List)   Gravity    (103 psi)
Polyester Molding     BMC 304, BMC
                                         0.85       1.9        2200
   Compound               350
Vinylester Molding    BMC 695, BMC
                                         1.25       1.72       2300
    Compound              840
     PEI (GP)          Ultem 1010        5.32       1.27       480
  PEI 30% (GF)         Ultem 2310        4.38       1.5        1250
PPS (65% GF/MR) Supec G323 Ryton         2.25       1.91       2100

  PPS (40% GF)       Supec G401 Ryton     3.5       1.66       1925

                      Valox, Ultradur,
  PBT (30% GF)                            1.4       1.51       1025
                          Celanex
  PET (30% GF)         Pelton, Petra     1.35       1.62       1400
Nylon66 (30-33%       Zytel, Ultramid,
                                         1.47       1.27       850
      GF)                 Vydyne
  Material        Molding           Material       Size of press          Machine Hour
                 Pressure           Constant          needed                   rates
               Range (103 psi)    tons/sq. in.     for 100 in2 of         w/operator and
                                 projected area   projected area (tons)        profit
                                                                             (national
                                                                             average)
   BMC            0.4 - 1.5           2.5                250                  $39.95
  PEI (GP)         10 - 20             5                 500                  $59.28
PEI 30% (GF)       10 - 20             6                 600                  $59.28
 PPS (65%
                   5 - 20              7                 700                  $59.28
  GF/MR)
PPS (40% GF)       5 - 20              6                 600                  $59.28

PBT (30% GF)        5 -15              2                 200                  $39.95

PET (30% GF)       4 - 20              3                 300                  $47.21

Nylon66 (30-
                   5 - 20              3                 300                  $47.21
  33% GF)
   Part Thickness           Thickness Ratio        BMC Reduces the
    Comparison           BMC / other material     amount of required
                       (for the same thickness)     material by...


  BMC vs. PEI (GP)              0.602                   39.8%
BMC vs. PEI (30% GF)            0.828                   17.2%
 BMC vs. PPS (65%
                                0.955                   4.5%
    GF/MR)
BMC vs. PPS (40% GF)            0.956                   4.4%

BMC vs. PBT (30% GF)            0.775                   22.5%

BMC vs. PET (30% GF)            0.860                   14.0%
BMC vs. Nylon66 (30-
                                0.728                   27.2%
     33% GF)
         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.
  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 1050’s 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.
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
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
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.
   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 80°C but can
    reach temperatures up to 120°C. 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.
Case Study
Questions

				
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