Insights on SMC / BMC / DMC
Start-ups
Sridhar NB
15th June 2012
SMC, BMC, DMC…
What are the names indicate
– SMC: Sheet moulding compound
– BMC : Bulk moulding compound
– DMC: Dough moulding
compound
Page 1
What can be produced?
For Trucks…Trunk Lid, Hood, Fenders,
Noise shield, Technical Frontend, Filter
Housing, Oil Sump
Page 2
What can be produced?
Page 3
SMC/ BMC Technology – design for success
• A fiber–reinforced composite material consisting of a
thermosetting resin, glass fibre reinforcement and
filler.
• Additional ingredients such as low-profile/ low-shrink
additives, cure initiators (peroxides), thickenning
additives, process additions mold release agents are
used.
Page 4
The complete Value chain
Formulation &
compounding
Testing
The machine
The press
Painting
Moulding
Component testing Tooling
Page 5
The Machine
• SMC/ BMC
(What we need to look….)
– Primary
• Glass content %
• Filler loading • Capital
• Sheet weight (gsm) Investment
• Production speed
• CTQs of the compound (requirements) • Cost varies
• Industry you like to cater
with need
• Future needs
• Quality control • Project
viability
– Secondary
• SMC cutting & slitting system
• Dosage, mixing & pumping units
• Measurements & control system
• Raw material storage
Page 6
Formulation & Compounding
• The Raw materials
– Resin
– Low shrink/ low profile additive
– Glass fiber
– Fillers
• Calcium carbonate, ATH, Talc, Barium Sulfate, Glass
Hollow Spheres
– Additives
• Wetting & dispersing
• Processing
• Anti-separation, Anti-settling
• Air release
Page 7
• Release agents
Shrinkage
Shrinkage:
• Polyester Resins have a
0,5
0,4
certain shrinkage during and 0,3
Linear Shrinkage, %
0,2
after the polymerization 0,1
– Influence on linear shrinkage -0,1
on final molded parts.
-0,2
-0,3
No LPA
Class A
Saturated PE
• Thermoplastic solutions and
Polystyrene
Saturated Polyester are add
to SMC/BMC formulations to
Examples for Linear Shrinkage
compensate the shrinkage. • Standard SMC ~ 0,5%
• With LS- an LP-Additives it is • (LS) Low Shrink SMC 0.05 – 0.25%
• (LP) Low Profile SMC 0 or Expansion
possible to adjust the desired • Class-A SMC Expansion ~ 0.1%
shrinkage. Expansion is also
possible.
Page 8
Types of LS - and LP - Additive
• Low Profile – Additive
– Polyvinylacetate (PVAc)
– Polymethylmetacrylate (PMMA)
– Saturated Polyester (PEs)
• Low Shrink – Additive
– Polystyrene
Page 9
Low profile : Impact on the product
SMC / with out LPA SMC / with LPA
Page 10
Types of additives
Release agent
Processing
Wetting
and
dispersing
Anti-separation
Air release
Anti-settling
Page 11
Wetting and dispersing
Dispersion
of fillers
Wetting and
and pigments
•Viscosity of
dispersing
the paste
additives
•Improved
distribution of
particles
•mechanical properties
•chemical resistance
•weathering
•etc.
Page 12
Filler Dispersion - Stabilisation
Agglomerate Primary Particle
Flocculate (Ideal Dispersion)
Dispersion
Flocculation
Flocculated Deflocculated
Page 13
Filler Dispersion - Stabilisation
Agglomerate Primary Particle
Flocculate (Ideal Dispersion)
Dispersion
Flocculation
Flocculated Deflocculated
Page 14
Processing additives
effect on
all formulation
Processing components
improved stable
additives
distribution of all
components in
the compound
• surface smoothness
• color homogeneity
• homogeneous surface
• etc.
Page 15
Processing additives for headlamps
The usage of materials at high temperature cause migration
of some of the components….. even after metalization and
coating.
This becomes visible as a haze on the cold part
(polycarbonate pane) inside a headlamp.
Called: FOGGING
Page 16
Processing additives for headlamps
FOGGING
BMC BMC
with stearates with additive
Page 17
Processing additives
With Additive – anti-separation effect
Control
1 phr additive
2 phr additive
Page 18
Processing additives
Impact on surface
Control formulation With additive formulation
40% mold coverage 40% mold coverage
Page 19
Processing additives
Impact on surface
Control formulation With additive formulation
80% mold coverage 80% mold coverage
Page 20
Processing additives
• Many types of processing problems and/or difficulties can
be solved through the use of processing additives.
• Changing the processing characteristics can open-up
windows of opportunity in many applications.
• Improved processing always leads to cost reduction.
Page 21
Filler for SMC/BMC
• CaCO3
– Mining product
– Density 2.70 g/cm³
• ATH
– The flame retardant effect
– Density 2.40 g/cm³
Page 22
Filler for SMC/BMC
• Barium sulphate BaSO4
– Filler for heavy weight applications / noise
reduction
– Density 4.50 g/cm³
• Glass hollow spheres
– Filler for light weight applications
– Density 0.37 g/cm³
Page 23
Equipment and Manufacturing
Resin and Color paste Resin and Color paste Final Mixture
+ Filler
Page 24
The mixer....
Dimensions:
Periherical speed > tbd m/s
Filling level
D - 0,5 x D
D - 2,0 x D
2 x D - 3,0 x D
Page 25
Storing, dosing, mixing: attention
needed…
Raw materials storage:
• Temperature, moisture, age
Dosing the paste:
• Constant quantity of Filler, MgO, Peroxide, Additives
Mixing the components:
• Constant parameters (Homogeneity, temperature)
Page 26
Equipment and Manufacturing
Thickening is essential for entire SMC process !
Thickening can influence:
• Impregnation of glass
• Separation of components (e.g. resin / LP-Additive)
• Flow in the mould / transport of fibers
• Handling of SMC (e.g. cutting, sticking)
Thickening of the SMC will be influenced by:
Resin / Additive, Acid number, MgO concentration (type, quantity),
Temperature / storage / time, Moisture content in the paste / filler
Page 27
Equipment and Manufacturing
Glass Fibers
Resin
Resin
Film Carrier Film
Cutter
Resin
Carrier Film
Resin Film
Impregnation Area SMC
Page 28
Manufacturig and Molding
Glass Fibers
Resin
Resin
Film Carrier Film
Cutter
Resin
Carrier Film
Resin Film
Impregnation Area SMC
Page 29
Thank you for your attention…
