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  1. Complete Composite Solutions AUTOMOTIVE

  2. BMC Offers High Performance with Low Cost BMC materials have been used in the automotive sector for more than 30 years and never has the need been greater for a high performance material that can meet the demands for BOTH cost and weight reduction than in today's automotive market. New demanding global fuel economy and tailpipe emissions regulations present severe challenges for today’s automotive engineers. BMC brings a unique balance properties and physical characteristics that help meet the challenge for current and future automotive applications. • High temperature resistance – Tg > 200C • Very high strength (fexural modulus greater than 18 GPA) • Low weight (30% lighter that equivalent aluminum parts) • Chemically resistant to most automotive fluids • Repeatable molded part dimensions (zero post mold shrink possible) • Excellent dimensional stability/tight tolerances (low CLTE) • Low warpage/excellent part flatness • Extremely high creep resistance (150C) • Excellent flammability resistance (UL94V-0) • Excellent electrical properties (insulating or conductive) • Low relative cost to alternative high performance materials • High temperature assembly possible (soldering, welding, etc.)

  3. Wide Range of Materials/Properties Bulk Molding Compounds Inc. is the worlds leading supplier of unsaturated polyester and vinyl ester based thermoset composite materials. BMC composite compounds are composed of various raw materials including resins, low profile additives, catalysts, pigments, mould release agents, fillers and fiber reinforcements. At BMCI we work closely with our customers to custom formulate our materials to deliver properties specific to each applications unique requirements to insure the correct balance of performance versus price. HIGHLY ENGINEERED POLYESTER AND VINYL ESTER THERMOSET COMPOSITES

  4. BMCI Global Footprint BMCI has 7 compounding facilities locating in North America, South America, Europe and Asia to serve the global automotive market. Each of these markets are supported by local BMC sales and technical service representatives. • USA - Chicago, IL, Perrysburg OH, • Mexico – Juarez, Mexico City • Brazil – Sao Paulo, • Germany – Hamburg, • China- Dongguan

  5. BMC Range of Properties • BMC’s unique blend of properties make them ideal for use in the extreme environments found in a wide variety of automotive applications. • Automotive Electrical and Lighting Systems • Under the Hood/Powertrain • Body Structures • Exterior Trim • Alternative Fuel Vehicles (Hybrid Electric/Fuel Cell)

  6. BMC vs. High Performance Materials BMC thermosets offer the most cost-effective performance at elevated temperatures under load, pressure, and chemical exposure in automotive applications compared to metal and engineered thermoplastics. Bulk molding compounds specifically offer“the best balance of physical properties at the lowest possible cost when compared to engineering thermoplastics and die cast metals.” (Average Material Attribute Comparison)

  7. BMC Range of Molding Processes BMC materials are produced in multiple forms, shapes, and sizes to meet each customers specific processing requirements. BMC materials can be processed by injection, compression, injection-compression, or resin transfer molding depending on the part size, shape, tolerancing, physical properties, and production volumes Tool life in most cases exceeds more than one million shots making it a very economical process when compared to metal die casting processes.

  8. BMCI In-House Technical Support Capabilities BMCI offers a range of application development support services to help select and/or develop materials with the right balance of properties and cost to meet requirements. Customization of formulations allows us to insure we are providing an optimized solution for each application with correct balance of properties vs. cost. A breadth of in house material development, testing, design engineering and prototyping enables us to help customers deliver solutions to meet the most demanding deadlines and requirements. • Material Selection • Material Formulation/Sampling • Full Service Materials Lab/Testing • Instron, Dynatup, Gas Chromatograph • FTIR, DSC, DMA, TGA • Engineering/Design • Materials/Product Training • Prototyping • Injection molding • Compression Molding • Rapid Prototyping • Full Service Tool Shop • Prototype and Production Tooling Fabrication • Conversion of Die Cast or Thermoplastic Molds for BMC Development

  9. BMC Range of Automotive Applications Spoilers, Air Vents ECU Enclosures Electric Motor Brush Holders, Armatures, Housings Capless Fuel Filler Engine Heat Shield/Beauty Covers Fuel Pumps Cylinder Head Covers Under Body Heat Shields Electronic Throttle Bodies Thermostat Housings Body Structural Inserts Head Lamp Reflectors Transmission Sump Pan Vacuum Pump Housing Transmission Thrust Washers Engine Front/Rear Covers Transmission Valve Body Transmission Linkage Cooling Pump Housing Starter End Cap Oil Pump Housing Oil Sump/Pan Oil Filter Housing Turbo Systems

  10. BMC Automotive Materials BMC materials used in Exterior, Lighting, Body Structure Applications. BMC Unsaturated Polyester Composites deliver excellent surface quality, painting and metalizing capabilities, tight tolerances, and high strength through temperatures in excess of 180°C, making them the logical choice for headlamp reflectors, exterior painted surfaces, heat shield shielding applications, and body structural supports.

  11. BMC Automotive Materials BMC materials used in high temperature under the hood applications. BMC Polyester and Vinyl Ester Composites offer very high glass transition temperatures in excess of 175°C making them a perfect fit for highly functional powertrain components that must maintain their properties and dimensions across their operating range as well as exposure to high vibration loads and harsh fluids. This makes them an excellent choice for engine sealing applications, electronic throttle bodies, pump housings, and turbo systems.

  12. BMC materials used in Conductive and Specialty Applications. As automotive systems and technologies evolve to meet new regulations, improve fuel economy, reduce environmental impacts and meet consumer demands, BMC’s flexibility in formulation enables high value material solutions in the most unique applications. From highly conductive composites for use in PEM Fuel Cell Bipolar Plates to very high strength composite materials with long term creep resistance meeting the extreme requirements in fuel cell stack end plates.

  13. BMC Sustainable Material Solutions The major environmental and social impacts of products throughout their life cycle along with the materials from which they are produced, is increasingly being recognized by customers across all market sectors. Many companies have embraced the importance of product sustainability, driven by environmental objectives and increased demand and prices of energy and resources. BMC materials offer immediate solutions to this demand with core products that offer one of the lowest energy content and cost solutions in light weight/high performance materials. BMCI has further responded to the demand for renewable materials by developing a line of bio-based BMC composites that employ the use of vegetable oils based resins, recycled fillers, and natural and organic fiber reinforcements. Green BMC Green BMC is manufactured using 100% soy based resin an doffers properties comparable to standard to standard grades at competitive costs. Green BMC also provides a solution to thermoset reprocessing but using pulverized molded BMC as 10% of its filler content.

  14. Forward Lighting Headlamp design is one of key components vehicle designers depend on to give vehicles their soul and identity. BMC composites have been the materials of choice for automotive headlamp manufacturers worldwide for more than 20 years, due to their superior performance, low cost and flexibility in design. BMC headlamp materials offer high temperature resistance combined with dimensional stability, and low coefficient of thermal expansion allowing for highly complex shapes and tight tolerances to be produced and maintained throughout their operational life. Typical application requirements • Temp : -40C to 180C • Tight tolerances and dimensional stability over operating range/Low CLTE • High stiffness up to 180C • Long term creep resistance • Process: Injection Molding • Material: BMC 304, 324 No Base Coat • Benefits of BMC: • Lowest Cost vs. Performance Material • No Machining Operations • Direct Metalized • No Base Coat • Low Fogging • Component Integration/Design Flexibility • High precision parts • Very good dimensional stability • Excellent rigidity

  15. Engine Sealing BMC Composites have demonstrated more than 20 years of success in replacing die cast metals in engine sealing applications. BMC’s high strength, and ability to maintain the required properties under long term exposure to high temperatures and hot engine oil make it the perfect choice to reduce cost and weight in applications such as cylinder head covers, oil pans, engine front and rear covers. Process: Injection or Compression Molding Material: BMC 675, 685, 695, 695HT Polyester and Vinyl Ester Composites Benefits of BMC over Al, Mg: • Piece Price Savings: 30-40% • Tooling Cost Reduction • Weight Savings: 25-30% • Improved NVH/Damping Properties Benefits of BMC over PA66 • Higher temperature capabilities • Improved flatness of sealing flange • Dimensional stability and creep resistance • Ease of coloring/aesthetics • Supports larger bolts spans • Excellent Flame Resistance (UL94 V-0) The stiffness of the material allows for less ribbing and total material use compared to Polyamide thermoplastics. Its inherent creep resistance allows for larger bolt spans, improved multi-planar sealing and/or added safety factor in maintaining constant surface pressures on the sealing flange preventing oil leakage and potential engine fires. • Typical application requirements • Temp : -40C to 130C • Tight tolerances and dimensional stability over operating range • Flexural creep resistance to maintain seal • Chemical resistance to under hood fluids • Long term exposure to hot engine oil

  16. Heat Shields/Engine Covers BMC materials are specified as thermal barriers based on the high temperature properties to protect and/or insure the proper long term function for fuel pumps, tanks, injectors as well as other components located close to exhaust systems such as spare tires. With the proliferation of turbo chargers in more consumer transportation applications, engine covers are being employed to protect consumers from the hot turbo and/or EGR components located near the top of engines. These localized high temperatures exceed the capability of traditional engineering thermoplastic materials. Process: Injection Molding or Compression Molding Material: BMC 304 Polyester, BMC 675, 695 Vinyl Ester Composite Benefits of BMC over PA, PPA: • Piece Price Savings: 15-60% • Higher Long Term Temperature Resistance Tg.> 200C • Very Low Warpage • No dimensional change with moisture absorption • Ease of coloring/aesthetics • Excellent Flame Resistance (UL94 V-0) Benefits of BMC over SMC: • Piece Price Savings • Less processing steps • Flexibility of processing (injection or compression) • Design Flexibility/Functional Integration

  17. Electronic Throttle Body/Air Control Valve The potential benefits of plastic throttle bodies over die cast aluminum are many, but the integrated functions, very tight air flow specifications and hence dimensional requirements combined with an extreme operational environment make realizing these benefits a tremendous challenge. BMCI has answered that challenge with the material innovation “Dimension X” a zero shrink polyester composite with very low CLTE that meets both long term durability and dimensional stability required in electronic throttle valves. In production since 2005 BMC Dimension X provides a high value material solution to meet the growing demands for cost and weight reduction while simultaneously delivering additional technical benefits over traditional aluminum parts. Process: Injection Molding Material: BMC Dimension X, BMC L420 Polyester Composite Benefits of BMC over Aluminum: • Piece Price Savings: 30-40% • Tooling Cost Reduction • Weight Savings: 25-30% • Improved icing / no heating • Eliminates coking performance issues • Equivalent or better dimensional tolerances • Print Tolerance: +/- 0.05mm flatness/roundness • Improved safety during crash • Reduced manifold dynamic loading

  18. Electronic Throttle Body/Air Control Valve • Typical application requirements • Temp : -40C to 150C • Very tight tolerances • Dimensional stability for concentricity of bore diameter over operating range • Creep resistance • Chemical resistance to under hood fluids • Benefits of BMC over High Performance ETP • Piece Price Savings: 30-75% • Zero out of mold shrinkage • Lower CLTE/better dimensional stability • Larger bores possible

  19. Electric Motor Components The number of electric motors in automobiles continues to grow at a rapid pace as vehicle technologies evolve to meet new market demands. From small motors including starter motors, windshield wiper motors, pump motors, window lift motors, power steering motor, fan motors, compressor motors, and actuator motors to larger motors such as traction motors found in electric vehicles. BMC offers customers a full range of high-performance composite solutions for motor coil forms, insulators, end caps, armature shaft insulators, brush holders, housings, stator encapsulations, etc. BMC materials offer properties such high heat resistance, arc resistance, flame resistance, moisture resistance, and electrical insulation required in these demanding applications. • Process: Injection Molding • Material: BMC 600, 604, 605, 620, 3001H, 1901 Polyester Composites • Benefits of BMC vs. High Performance Thermoplastics: • Piece Price Savings: 40-50% • Improved dimensional stability • Better Creep Resistance • Improved property retention over service life • Reduced noise • Higher Dielectric Strengths • Lower Moisture Absorption • Typical application requirements • Tight tolerances and dimensional stability over operating range • 150°C continuous use temperature • High mechanical strength/stiffness • Chemical resistance • Good Resistivity/High dielectric strength • Flammability resistance (UL94V-0) and Arc Resistance

  20. BULK MOLDING COMPOUNDS, INC.“Complete Composite Solutions” Contact: Jim Cederstrom, Automotive Business Development Phone: 248.766.7111 Email: jim_c@bulkmolding.com Please continue to view automotive photo gallery

  21. photo gallery

  22. forward lighting

  23. airbag control unit housing

  24. transmission stator

  25. Electronic throttle control housing

  26. motor armatures

  27. valve cover

  28. starter motor

  29. electrical motor housing

  30. Fluid impeller

  31. BMC Automotive Components gear shift linkage