The Needs of the Thermoset Supply Chain – Today and into the Future

Presented by:• Doreen Lettau, Dickten Masch Plastics• Rick Faulk, Bulk Molding Compounds, Inc.• Carl Lider, Dickten Masch Plastics

Introduction:

A robust supply chain is now more important than ever as the market continues to rebound.

The Current State of the Supply Chain

Doreen Lettau, Dickten Masch Plastics

Supply Chain Trends

• New dynamics• New considerations• Recent changes in relationships

Molder/Material Supplier Partnerships

• Pros and cons of in-house compounding• Pros and cons of molder/material supplier

partnerships– Enables molder to be material agnostic– Enables each to be experts in their own fields

Molder / Compounder

OEM

Molder / Compounder

Auto ApplianceElectric

(Products / Applications)

Molder / material supplier partnerships provide twice the knowledge, experience and reach to grow thermoset products and applications. OEM

CleanTechnology

Building & ConstructionHealthcareAuto ApplianceElectric

BMCDMP

(Products / Applications)

Molder / Material Supplier Partnership

Tooling in the Supply Chain

• Outsourcing tooling, especially overseas, is becoming more predominant.

• China’s capabilities have come a long way in the last 5 years.– But it’s still crucial to be involved in process.

Chinese Tooling

Prepare for this trend continuing into the future.– Molders are taking the reins of managing tool

builds with china.– Molders have developed a sound program of

doing this.

Molders at the Hub

• Important role of experienced molders as a logistical supply chain hub– Maximize efficiencies– Reduce costs– Identify the best solutions– Take ownership of other components

• Management of supply chain & logistics

A Material Suppliers Perspective

Rick Faulk, Bulk Molding Compounds, Inc.

Gas, Oil, & Energy

Food Prices on the Rise

Most in 36 Years!

LME Aluminum 3 Year Price Chart

What’s Next?

• Cost cutting measures• Efficiency improvements• Overhead structures

• Identify areas where thermosets offer value!

Case Study #1

Commutator End Bracket Conversion

Material Cost / Part:

Molding Cost / Part:

Secondary Gate Trimming:

Secondary Machining:

Scrap @ 3%

Total Cost / Part:

$0.19

$0.281

$0.01

$0.035

$0.015

$.531

$0.14

$0.225

-

-

$0.011

$.376

Aluminum BMC

30% SAVINGS

Thermoset Focus• Thermoset background and material composition• Market participation & applications• Tooling & part design• Flow modeling / design verification• Molding technology – cure sensors & pressure

measurement• Molding processes – injection, compression, transfer

(hands on available)• Finishing & secondary operations• Analytical test methods & capability

Increasing Momentum

• Material is cleaner and more advanced than the current perception in the marketplace

• Compliant materials– Green movement – recyclable material– NSF & FDA compliant materials– ROHS compliance– Reach compliant– NSF & UL listings

Bulk Molding Compound

Resin(UP or VE)

ShrinkageControl

MineralFillers

FiberReinforcement

CuringAgents Pigments

What are thermoset molding compounds?

A thermoset molding compound is a product that undergoes an irreversible crosslinking reaction during the molding process that converts it to an infusible solid state.

BMC Components

= Potential for renewable or recycled inputs !

Recycled BMC Molded Components

Electrical Market

• Clean energy• Smart grid technology• UV resistant• Thermal stability• UL listed• Electrical properties

Automotive Market

• Electric vehicles• Infrastructure• Insulating properties• Weather resistant • Chemical resistant• Paint / powder coat

Appliance Market

• Stainless steel look• Cost effective• Cold to the touch• Rigid / high modulus• Heat & stain resistant

Plumbing Market

• Brass replacement – no lead

• Non-corrosive• Molded in color• NSF / FDA approvals

Advancements in Precision Technology

Carl Lider, Dickten Masch Plastics

Examination of the Total Value StreamWhere have we been thus far?

Examination of the Total Value StreamWhere are the opportunities throughout the

whole value stream?

A Scientific Approach to Molding

• Process monitoring and parameter control• Focus on output rather than input• Batch variation• Dielectric cure sensing

Importance of Robust Tooling

• Design standards are crucial in thermosets.• In-mold tool intelligence• Gating, flow, runner, vacuum, and other

design considerations

A Look into the Future

• As we analyze data, we find better ways of putting controls in place.

• Thermosets are currently an underutilized material.