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Bulk Molding Compounds, Inc. Complete Composite Solutions.

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Presentation on theme: "Bulk Molding Compounds, Inc. Complete Composite Solutions."— Presentation transcript:

1 Bulk Molding Compounds, Inc. Complete Composite Solutions

2 BMC Injection- Molded Motor Brackets

3 BMC vs. Die Cast Metals Reduced Cycle Times / Reduced Manufacturing Cost Reduced Cycle Times / Reduced Manufacturing Cost Thermal / Dimensional Stability Thermal / Dimensional Stability Noise Reduction Noise Reduction Weight Reduction Weight Reduction Elimination of Costly Secondary Machining Operations Elimination of Costly Secondary Machining Operations Lower Tooling Costs / Longer Tool Life Lower Tooling Costs / Longer Tool Life Greater Design Freedom Greater Design Freedom = 30-50% Cost Savings over Die-Cast Metal Reduced Cycle Times / Reduced Manufacturing Cost Reduced Cycle Times / Reduced Manufacturing Cost Thermal / Dimensional Stability Thermal / Dimensional Stability Noise Reduction Noise Reduction Weight Reduction Weight Reduction Elimination of Costly Secondary Machining Operations Elimination of Costly Secondary Machining Operations Lower Tooling Costs / Longer Tool Life Lower Tooling Costs / Longer Tool Life Greater Design Freedom Greater Design Freedom = 30-50% Cost Savings over Die-Cast Metal ADVANTAGES

4 Thermal / Dimensional Stability RIGIDITY AT ELEVATED TEMPERATURES BMC Composites vs. Engineering Thermosets RIGIDITY AT ELEVATED TEMPERATURES BMC Composites vs. Engineering Thermosets

5 Thermal / Dimensional Stability BMCs offer significant acoustical insulation over metals Automotive valve cover conversion from aluminum to BMC 25% Reduction in Valve-train noise in BMC !

6 Part Weight Reduction

7 BMC Polyester : 1.7 – 2.05s.g. Die-Cast Aluminum : 2.6s.g. Die-Cast Zinc : 6.9s.g. BMC Polyester : 1.7 – 2.05s.g. Die-Cast Aluminum : 2.6s.g. Die-Cast Zinc : 6.9s.g. Lower Specific-Gravity with BMC Reduction In Assembly / Unit Weight Lower Raw Material Content $ Reduction in Shipping Weight / Cost $ Reduction In Assembly / Unit Weight Lower Raw Material Content $ Reduction in Shipping Weight / Cost $

8 No Secondary Machining BMC Parts molded GATE FREE. No Secondary Gate Removal No material overflows required for BMC. No secondary trim-die operation required Critical dimensions / tolerances typically held as-molded. No secondary machining operations required. BMC Parts molded GATE FREE. No Secondary Gate Removal No material overflows required for BMC. No secondary trim-die operation required Critical dimensions / tolerances typically held as-molded. No secondary machining operations required. Package At Press!

9 Tooling Friendly BMC Polyesters are very tooling-friendly offering the following advantages over metals: 4-5 Times Longer Mold Life Higher Cavitations Significantly lower PM & Repair Costs Allows for use of more complex moving actions (Slides etc.) Allows for use of manifold systems for material delivery to cavities 4-5 Times Longer Mold Life Higher Cavitations Significantly lower PM & Repair Costs Allows for use of more complex moving actions (Slides etc.) Allows for use of manifold systems for material delivery to cavities

10 Greater Design Freedom The flow characteristics and related moldability of BMCs allows for the formation of more complex part geometries. This gives the part designer increased freedom to: Incorporate the net-shapes required to optimize the part / assembly design Incorporate the net-shapes required to optimize the part / assembly design Reduce the number of components through consolidation of parts Reduce the number of components through consolidation of parts The flow characteristics and related moldability of BMCs allows for the formation of more complex part geometries. This gives the part designer increased freedom to: Incorporate the net-shapes required to optimize the part / assembly design Incorporate the net-shapes required to optimize the part / assembly design Reduce the number of components through consolidation of parts Reduce the number of components through consolidation of parts

11 Commutator End Brackets / End Bells Fan End Brackets Fan End Brackets Clamshell Motors Clamshell Motors Motor End Plates Motor End Plates Cup Style Motor Housings Cup Style Motor Housings Fan / Diffuser End Caps Fan / Diffuser End Caps Brush Plates Brush Plates Brush Cartridge Housings Brush Cartridge Housings Commutator End Brackets / End Bells Fan End Brackets Fan End Brackets Clamshell Motors Clamshell Motors Motor End Plates Motor End Plates Cup Style Motor Housings Cup Style Motor Housings Fan / Diffuser End Caps Fan / Diffuser End Caps Brush Plates Brush Plates Brush Cartridge Housings Brush Cartridge Housings Motor Bracket Configurations

12 Commutator End Bracket / End Bell Integrated Brush Box Features As-Molded Bearing Bore, Brush Boxes & Field Pads Integrated Brush Box Features As-Molded Bearing Bore, Brush Boxes & Field Pads

13 Fan End Brackets Integrated Airflow Features As-Molded Bearing Bore & Field Pads Mounting Points Suitable for Motor Assembly Integrated Airflow Features As-Molded Bearing Bore & Field Pads Mounting Points Suitable for Motor Assembly

14 Clamshell Motor Housings As-Molded Bearing Bore Advantages in Small Hand- Held Applications Weight Reduction Noise / Vibration Reduction Ground-Path Insulation As-Molded Bearing Bore Advantages in Small Hand- Held Applications Weight Reduction Noise / Vibration Reduction Ground-Path Insulation

15 Motor End Plates As-Molded Bearing Bore Weight Reduction on Large Motor Configurations As-Molded Bearing Bore Weight Reduction on Large Motor Configurations

16 Cup Style Motor Housings Reduced Number of Components in Assembly More Consistent Motor Alignment As-Molded Bearing Bore, Brush Boxes & Field Pads Integrated Airflow Features Reduced Number of Components in Assembly More Consistent Motor Alignment As-Molded Bearing Bore, Brush Boxes & Field Pads Integrated Airflow Features

17 Fan / Diffuser End Caps * Accommodates the formation of more complex / efficient airflow geometries

18 Brush Plates / Cartridge Housings Superior Properties over Thermoplastics

19 BMC Motor Bracket Materials BMC Materials currently supplied into motor bracket applications: BMC 400 BMC 620 BMC 1412 T40-(18) T40-(20) T40-(25) BMC 400 BMC 620 BMC 1412 T40-(18) T40-(20) T40-(25) BMCI can custom-formulate materials as-necessary to meet specific applications.

20 Case Study #1 Commutator End Bracket Conversion Material Cost / Part: Molding Cost / Part: Secondary Gate Trimming: Secondary Machining: 3% Total Cost / Part: Material Cost / Part: Molding Cost / Part: Secondary Gate Trimming: Secondary Machining: 3% Total Cost / Part: $.19 $.281 $.01 $.035 $.015 $.531 $.19 $.281 $.01 $.035 $.015 $.531 $.14 $ $.011 $.376 $.14 $ $.011 $.376 Aluminum BMC 30% SAVINGS

21 Case Study #2 Commutator End Bell Conversion/Redesign Material Cost / Part: Molding Cost / Part: Secondary Gate Trimming: Secondary Machining: 3% Brush Plate (2 nd Part): Total Cost / Part: Material Cost / Part: Molding Cost / Part: Secondary Gate Trimming: Secondary Machining: 3% Brush Plate (2 nd Part): Total Cost / Part: $.08 $.22 $.01 $.035 $.001 $.217 $.563 $.08 $.22 $.01 $.035 $.001 $.217 $.563 $.133 $.23 - $ $.374 $.133 $.23 - $ $.374 Aluminum BMC Brush Boxes incorporated into BMC part as 1-Piece Design 34% SAVINGS

22 Mounting Hardware for BMCs Self-Tapping Screws Thread-Cutting Never Thread-Forming BT-Style or Type-23 Style recommended High-Low thread preferred Hole diameter p/s over root-diameter of screw Minimum thread engagement 2 ½ X screw diameter Hole depth 125% to 150% of screw engagement depth Mounting boss diameter minimum 2X major screw diameter Self-Tapping Screws Thread-Cutting Never Thread-Forming BT-Style or Type-23 Style recommended High-Low thread preferred Hole diameter p/s over root-diameter of screw Minimum thread engagement 2 ½ X screw diameter Hole depth 125% to 150% of screw engagement depth Mounting boss diameter minimum 2X major screw diameter

23 Design Considerations for BMC Minimum Recommended Wall Stock.070 Recommended Nominal Wall Stock Minimum draft 1-degree P/S (Excluding Bores & Brush Boxes) Consistency of Wall stock Core-out Thick Sections Wherever Possible Fillet Radii Wherever Possible Line-of-Draw Features Wherever Possible Minimum Recommended Wall Stock.070 Recommended Nominal Wall Stock Minimum draft 1-degree P/S (Excluding Bores & Brush Boxes) Consistency of Wall stock Core-out Thick Sections Wherever Possible Fillet Radii Wherever Possible Line-of-Draw Features Wherever Possible

24 The BMC Advantage Faster Cycling Longer Tooling Life No Costly Secondary Machining Weight Reduction Noise Reduction Dimensional Stability Design Versatility Faster Cycling Longer Tooling Life No Costly Secondary Machining Weight Reduction Noise Reduction Dimensional Stability Design Versatility BMC offers cost savings without sacrifice.


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