bulk molding compounds, inc

Bulk Molding Compounds, Inc.

Bulk Molding Compounds, Inc.

‘Complete

Composite

Solutions’

‘Complete

Composite

Solutions’

BMC Injection- Molded Motor Brackets

BMC Injection- Molded Motor Brackets

BMC vs. Die Cast MetalsBMC vs. Die Cast MetalsBMC vs. Die Cast MetalsBMC vs. Die Cast Metals

• Reduced Cycle Times / Reduced Reduced Cycle Times / Reduced Manufacturing CostManufacturing Cost

• Thermal / Dimensional StabilityThermal / Dimensional Stability

• Noise ReductionNoise Reduction

• Weight ReductionWeight Reduction

• Elimination of Costly Secondary Machining Elimination of Costly Secondary Machining OperationsOperations

• Lower Tooling Costs / Longer Tool LifeLower Tooling Costs / Longer Tool Life

• Greater Design FreedomGreater Design Freedom

= 30-50% Cost Savings over Die-Cast Metal

• Reduced Cycle Times / Reduced Reduced Cycle Times / Reduced Manufacturing CostManufacturing Cost

• Thermal / Dimensional StabilityThermal / Dimensional Stability

• Noise ReductionNoise Reduction

• Weight ReductionWeight Reduction

• Elimination of Costly Secondary Machining Elimination of Costly Secondary Machining OperationsOperations

• Lower Tooling Costs / Longer Tool LifeLower Tooling Costs / Longer Tool Life

• Greater Design FreedomGreater Design Freedom

= 30-50% Cost Savings over Die-Cast Metal

ADVANTAGESADVANTAGES

Thermal / Dimensional Thermal / Dimensional StabilityStability

Thermal / Dimensional Thermal / Dimensional StabilityStability

RIGIDITY AT ELEVATED TEMPERATURESBMC Composites vs. Engineering Thermosets

RIGIDITY AT ELEVATED TEMPERATURESBMC Composites vs. Engineering Thermosets

Thermal / Dimensional Thermal / Dimensional StabilityStability

Thermal / Dimensional Thermal / Dimensional StabilityStabilityBMCs offer significant acoustical insulation BMCs offer significant acoustical insulation

over metalsover metals

Automotive valve cover conversion from aluminum

to BMC

Automotive valve cover conversion from aluminum

to BMC

25% Reduction in Valve-25% Reduction in Valve-train noise in BMC !train noise in BMC !

Part Weight Part Weight ReductionReduction

Part Weight Part Weight ReductionReduction

Part Weight Part Weight ReductionReduction

Part Weight Part Weight ReductionReduction

• 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 Lower Specific-Gravity with BMCBMC

Lower Specific-Gravity with Lower Specific-Gravity with BMCBMC

• 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 $

No Secondary MachiningNo Secondary MachiningNo Secondary MachiningNo 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!Package At Press!

Tooling FriendlyTooling FriendlyTooling FriendlyTooling Friendly

BMC Polyesters are very “tooling-friendly” BMC Polyesters are very “tooling-friendly” offering the following advantages over offering the following advantages over metals:metals:

BMC Polyesters are very “tooling-friendly” BMC Polyesters are very “tooling-friendly” offering the following advantages over offering the following advantages over metals: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

Greater Design FreedomGreater Design FreedomGreater Design FreedomGreater Design Freedom

The flow characteristics The flow characteristics and related moldability and related moldability of BMCs allows for the of BMCs allows for the

formation of more formation of more complex part complex part geometries.geometries.

This gives the part This gives the part designer increased designer increased

freedom to:freedom to:

• Incorporate the net-Incorporate the net-shapes required to shapes required to optimize the part / optimize the part / assembly designassembly design

• Reduce the number of Reduce the number of components through components through consolidation of parts consolidation of parts

The flow characteristics The flow characteristics and related moldability and related moldability of BMCs allows for the of BMCs allows for the

formation of more formation of more complex part complex part geometries.geometries.

This gives the part This gives the part designer increased designer increased

freedom to:freedom to:

• Incorporate the net-Incorporate the net-shapes required to shapes required to optimize the part / optimize the part / assembly designassembly design

• Reduce the number of Reduce the number of components through components through consolidation of parts consolidation of parts

Commutator End Brackets / End BellsCommutator End Brackets / End Bells

Fan End BracketsFan End Brackets

Clamshell Motors Clamshell Motors

Motor End PlatesMotor End Plates

“ “Cup” Style Motor HousingsCup” Style Motor Housings

Fan / Diffuser End CapsFan / Diffuser End Caps

Brush PlatesBrush Plates

Brush Cartridge HousingsBrush Cartridge Housings

Commutator End Brackets / End BellsCommutator End Brackets / End Bells

Fan End BracketsFan End Brackets

Clamshell Motors Clamshell Motors

Motor End PlatesMotor End Plates

“ “Cup” Style Motor HousingsCup” Style Motor Housings

Fan / Diffuser End CapsFan / Diffuser End Caps

Brush PlatesBrush Plates

Brush Cartridge HousingsBrush Cartridge Housings

Motor Bracket Motor Bracket ConfigurationsConfigurationsMotor Bracket Motor Bracket ConfigurationsConfigurations

Commutator End Bracket / End Commutator End Bracket / End BellBell

Commutator End Bracket / End Commutator End Bracket / End BellBell

• Integrated Brush Box Features

• As-Molded Bearing Bore, Brush Boxes & Field Pads

• Integrated Brush Box Features

• As-Molded Bearing Bore, Brush Boxes & Field Pads

Fan End BracketsFan End BracketsFan End BracketsFan 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

Clamshell Motor HousingsClamshell Motor HousingsClamshell Motor HousingsClamshell 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

Motor End PlatesMotor End PlatesMotor End PlatesMotor End Plates

• As-Molded Bearing Bore

• Weight Reduction on Large Motor Configurations

• As-Molded Bearing Bore

• Weight Reduction on Large Motor Configurations

““Cup” Style Motor Cup” Style Motor HousingsHousings

““Cup” Style Motor Cup” Style Motor HousingsHousings

• 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

Fan / Fan / Diffuser End Diffuser End CapsCaps

Fan / Fan / Diffuser End Diffuser End CapsCaps

* Accommodates

the formation of

more complex /

efficient airflow

geometries

* Accommodates

the formation of

more complex /

efficient airflow

geometries

Brush Plates / Cartridge Brush Plates / Cartridge HousingsHousings

Brush Plates / Cartridge Brush Plates / Cartridge HousingsHousings

Superior Properties over ThermoplasticsSuperior Properties over ThermoplasticsSuperior Properties over ThermoplasticsSuperior Properties over Thermoplastics

BMC Motor Bracket MaterialsBMC Motor Bracket MaterialsBMC Motor Bracket MaterialsBMC Motor Bracket Materials

BMC Materials currently supplied into BMC Materials currently supplied into motor bracket applications:motor bracket applications:BMC Materials currently supplied into BMC Materials currently supplied into motor bracket applications: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 BMCI can custom-formulate materials as-necessary to meet specific applications.applications.

BMCI can custom-formulate materials as-necessary to meet specific BMCI can custom-formulate materials as-necessary to meet specific applications.applications.

Case Study #1Case Study #1Commutator End Bracket Commutator End Bracket

ConversionConversion

Case Study #1Case Study #1Commutator End Bracket Commutator End Bracket

ConversionConversion

Material Cost / Part:

Molding Cost / Part:

Secondary Gate Trimming:

Secondary Machining:

Scrap @ 3%

Total Cost / Part:

Material Cost / Part:

Molding Cost / Part:

Secondary Gate Trimming:

Secondary Machining:

Scrap @ 3%

Total Cost / Part:

$.19

$.281

$.01

$.035

$.015

$.531

$.19

$.281

$.01

$.035

$.015

$.531

$.14

$.225

-

-

$.011

$.376

$.14

$.225

-

-

$.011

$.376

AluminumAluminum BMCBMC

30% SAVINGS30% SAVINGS30% SAVINGS30% SAVINGS

Case Study #2Case Study #2Commutator End Bell Commutator End Bell Conversion/RedesignConversion/Redesign

Case Study #2Case Study #2Commutator End Bell Commutator End Bell Conversion/RedesignConversion/Redesign

Material Cost / Part:

Molding Cost / Part:

Secondary Gate Trimming:

Secondary Machining:

Scrap @ 3%

Brush Plate (2nd Part):

Total Cost / Part:

Material Cost / Part:

Molding Cost / Part:

Secondary Gate Trimming:

Secondary Machining:

Scrap @ 3%

Brush Plate (2nd Part):

Total Cost / Part:

$.08

$.22

$.01

$.035

$.001

$.217

$.563

$.08

$.22

$.01

$.035

$.001

$.217

$.563

$.133

$.23

-

-

$.011

-

$.374

$.133

$.23

-

-

$.011

-

$.374

AluminumAluminum BMCBMC

Brush Boxes incorporated into BMC part as 1-Piece Design

Brush Boxes incorporated into BMC part as 1-Piece Design

34% SAVINGS34% SAVINGS34% SAVINGS34% SAVINGS

Mounting Hardware for BMCs Mounting Hardware for BMCs Mounting Hardware for BMCs 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 +.002” 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 +.002” 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

Design Considerations for Design Considerations for BMCBMC

Design Considerations for Design Considerations for BMCBMC

Minimum Recommended Wall Stock .070”

Recommended Nominal Wall Stock .100” - .125”

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 .100” - .125”

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

The BMC AdvantageThe BMC AdvantageThe BMC AdvantageThe 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.

BMC offers cost savings without

sacrifice.