The maintenance of SMC molds is an important measure to ensure the normal operation of the mold and prolong its service life.
SMC mold(sheet molding compound) is an important manufacturing tool used to produce various composite material products. However, these molds are subject to the risk of wear and damage during the production process, and attention needs to be paid to their maintenance and maintenance to ensure their long-term use, product quality and production efficiency.
Here are some detailed tips on SMC mold maintenance and maintenance:
1. Clean the surface and interior of the mold regularly: Before and after using the SMC mold, the mold needs to be cleaned. First, use air pressure to remove dust and dirt from the surface of the mold. Then, clean the surface and interior of the mold with a specific cleaning agent. Regular cleaning of molds will ensure they remain in top condition and reduce damage and wear from accumulated dirt and impurities.
2. Keep the mold surface lubricated: Proper lubricant can reduce wear and tear on the mold surface and reduce friction. Lubricant should be applied thinly on the surface of the mold to prevent too much lubricant from entering the mold and affecting product quality.
3. Regularly inspect the surface and interior of the mold: Regularly inspect the surface and interior of the mold for cracks, scratches, wear, or other damage. Finding and repairing these problems in time can avoid more serious damage and prolong the service life of the mold.
4. Keep the mold in a dry environment: SMC molds should be stored in a dry and ventilated environment. An environment with high humidity may cause rust and corrosion on the surface of the mold, affecting the service life of the mold.
5. Avoid overloading the mold: When using SMC molds, it is necessary to avoid overloading. Overloading may cause mold deformation, wear and breakage, causing irreversible damage to the mold.
6. Regular replacement of molds: SMC molds also need to be replaced regularly to ensure product quality and production efficiency. The service life of a mold depends on its material, manufacturing process and usage. Mold replacement should be considered when there is visible damage or wear to the mold surface, or when the product begins to change in size and shape.
In short, the maintenance and maintenance of SMC molds is an important measure to ensure the normal operation of the mold and prolong its service life. Regular cleaning, lubrication and inspection of molds, as well as avoiding overloading, can ensure the normal operation and efficient production of molds. Maintaining and maintaining molds can help companies reduce production costs, improve product quality, and ensure the safety of the manufacturing process.
MDC Mould is a professional mould manufacturer, especially of SMC molds.The molds developed by our company have short (2-4 minutes) cycle time and the use of machined tool steel molds supports a program volume of more than 500,000 units per year. Our company adheres to the concept of professionalism and integrity, and will focus on developing higher-quality, higher-tech molded FRP molds in the future.
Our molds not only have high difficulty, long service life and short cycle time, but also have reasonable price, timely delivery and considerate service, which are favored by customers at home and abroad. If you have any needs, welcome to contact us.
MDC mould has been designing and manufacturing moulds for Sheet Moulding Compound (SMC) and Bulk Moulding Compound (BMC) materials since the 1990s.
Over the past few decades, composite materials have become important in traffic engineering, automotive, aerospace technology, electrical engineering and other industries. Composites based onSheet Molding Compound (SMC)and Bulk Molding Compound (BMC) technologies allow the creation of small and medium-sized parts with the highest mechanical properties and heat resistance requirements.
Thermoset materials such as SMC, BMC, etc have excellent physical properties when getting compression molding. Structural parts molded from BMC or SMC can be replaced for metal products at the condition of weight reduction without lowering strength. Excellent heat resistance, compression strength, and dimensional stability are all advantages of compression molding materials.
Difference Between SMC and BMC Materials
Before the introduction begins, there are a few more proper nouns you need to know:
Polyester resin: an adhesive that provides three-dimensional crosslinking during processing, connects individual components, and plays an important role in achieving desired thermomechanical properties;
Mineral fillers: ensuring the transport of glass fibers during the flow of the material, can significantly reduce its cost and, in the case of aluminum hydroxide, significantly improve the refractoriness of the material;
Glass fiber: provides the mechanical strength of the product;
Catalyst: Provides initiation of three-dimensional cross-linking chemical reactions. The correct choice of catalyst is the most important condition for obtaining high-quality parts without underpressure, cracks and voids.
SMC material
SMC (Sheet Molding Compound) – Sheet material containing resins, fillers, reinforcing fibers. SMC is a material that can be pressed and processed at a high temperature of 120-160 SMC °C. The SMC is protected by a polymer film on both sides. Thickening agent, inorganic filler, initiator, additive, and pigment were added to the unsaturated polyester resin to make a mixture of resin, impregnated with short-cut fiber or felt piece, covered with PE film on both sides, after thickening, a thin sheet molded plastics were prepared. Unlike woven glass materials, SMC is not reinforced with bonded glass fibers. Because the glass fiber length is significantly longer than that of BMC, SMC has lower flow properties but higher strength properties. By using a chemical-resistant resin, a pressed material with high weather resistance can be obtained.
Typical SMC structure:
Fiberglass (15-50mm) – 27%;
Filler (talc) – 40%;
Resins (polyester, vinylester) – 28%;
Other additives – 5%.
Usually fibers in SMC products have two orientations. SMC also has the following varieties:
SMC LP is a thin material that can get products with high surface quality;
SMC LS – low shrinkage material;
HSSMC is a high strength material.
Depending on the specific product, different types of SMC can be used, each with different characteristics. The common denominator is minimal technical shrinkage and high impact strength. The significant advantages of SMC products compared to steel are high corrosion resistance and low specific gravity. SMC is processed into large-sized body parts by direct compression. During the pressing process, the pre-cut material is placed into the mold. The clamping time is 2-3 minutes, and the heating temperature is about 150 ℃.
The main application areas of SMC are: automotive industry, traffic engineering, lighting engineering, electrical network. The most notable achievement is the use of oil pans and valve covers made of SMC by car companies in production truck models. The following is a list of auto parts that can be manufactured with compression molds.
Automotive interior parts: instrument panel, door panel, glove box, car seat and various protection panels.
Structural and functional components: fuel tank, coolant tank, air filter cover, fan blades, intake pipe and cylinder head.
In addition to auto parts, SMC molding is also used to produce bathroom accessories, water tank accessories, motorcycle accessories, fitness equipment parts and meter housings.
BMC material
BMC (Bulk Molding Compound) – A special paste-like material containing resin BMC, fillers, and reinforcing fibers. It mixes a variety of inert fillers, fiber-reinforced materials, catalysts, stabilizers and pigments in thermosetting plastics to form a gluey “putty like” composite material for pressing or injection molding. The glass fibers in BMC are shorter than those in SMC, so the BMC material flows even better than SMC, and can be made into a better finish or more complex materials. BMC features light weight, electrical insulation, fire resistance, corrosion resistance, heat resistance, weather resistance, low shrinkage, stable dimensional control, good fluidity, and a variety of special properties combined into one, making bulk molding compound (BMC) the most ideal of materials to manufacture smaller but more complex and precise products used in various industries.
Typical BMC structure:
Fiberglass (5-20mm) – 20%;
Filler (talc) – 45%;
Resins (polyester, vinylester) – 30%;
Other additives – 5%.
BMC is a material that can be processed by pressing or injection. During pressing, metal is used to heat the substrate. Pressures from 30 to 100 atmospheres. The heating temperature is 100-160°C. The mold closing time is 2-3 minutes, during which heating occurs and polymerization is initiated. Injection molding uses a screw injection molding machine to feed material into a closed mold cavity.
BMC technology has also been widely used in the production of complex-shaped parts, such as pump casings, electrical components, etc.
Although there are differences between the two forms of material, both are suitable options for compression molding. In both cases, MDC mould offers SMC and BMC mould options that accompany MDC mould’s commitment to excellence.
SMC VS BMC
In general, when the mechanical properties of the products, including tensile strength, bending strength and impact strength, etc. are higher, the surface area of the products is larger, and the lightweight of the products is higher, SMC will be selected.
In general, the requirements for economic cost control are too high, and the mechanical strength requirements are lower than SMC requirements; When the electrical properties and flame retardant properties of the products are higher; When the surface area of the product itself is small, people usually choose BMC.
SMC is light weight and high strength
Size stability of BMC
SMC integration degree is high, design freedom
BMC has good water and solvent resistance
SMC has strong corrosion resistance
High heat resistance of BMC
SMC excellent heat resistance and coating
Aging resistance of BMC
SMC pressing process is simple
The electrical performance of BMC is outstanding
MDC mould has been designing and manufacturing moulds for Sheet Moulding Compound (SMC) and Bulk Moulding Compound (BMC) materials since the 1990s. MDC Mould is one of well-known mold makers in china. With the most advanced production equipment and technology, it enables us to manufacture the best quality molds. MDC has a long history in the glass fiber compression molding industry. We are committed to the design, development and production of stampers, as well as provide technical support to customers worldwide, Our aim is to become the best supplier of stable, high-performance SMC mould and BMC mould.
Nowadays, many SMC suppliers are trying to make low density material. This new SMC formulation will be allowed engineers to get ability to design with a low specific gravity material without mechanical properties, surface qualities, etc.
Nowadays, many SMC suppliers are trying to make low-density material. This SMC formulation will be allowed you to get the ability to design with a low specific gravity material without mechanical properties, surface qualities, etc.
Traditional SMC materials used in Class A applications have a density of 1.8 g/cm2 to 1.9 g/cm2 — around 30% less than aluminum and 75% less than steel, but relatively high for plastic material. Because SMC parts must be thicker than steel or aluminum, actual weight savings are smaller than these figures would indicate. The classic method for reducing density in SMC is to add hollow glass microspheres, and formulations are in production for unexposed, lightly loaded components with densities as low as 1.3 g/cm2.
What are the common types of SMC formulations?
Basic formulations.
Formulation according to production process and product performance.
Formulation specially for a particular product.
Depending on the range of products, requirements and the specific conditions of each unit, the components and dosage ratios in the table can be changed in different ways.
SMC Formulation
Recipe
General/Serving
Corrosion Resistant/Part
Low shrinkage portion
Polyester resin
Phthalate 100
Isophthalic Acid 100
Phthalate 100
Initiator
Tt-Butyl Benzoyl Peroxide 1
/
/
Low shrinkage additives
Thermoplastic Polymers 0 – 10
Thermoplastic Polymer 25 – 40
/
filler
Calcium Carbonate 70 – 120
Barium Sulfate 60 – 80
Calcium Carbonate 120 – 180
Internal release agent
Zinc stearate 1~2
Zinc stearate 1~2
Zinc stearate 3~4
Thickeners
MgO or Mg(OH)2, Ca(OH)2, 1-2
MgO or Mg(OH)2,Ca(OH)2,0.5-1
MgO or Mg(OH)2, Ca(OH)2, 1-2
Stabilizer
Appropriate amount
Appropriate amount
Appropriate amount
Fiberglass
25% ~ 35%
/
/
How to choose unsaturated polyester resin for smc?
The selection of unsaturated polyester should meet the following requirements:
Low viscosity or solid powder, convenient for glass fiber impregnation or mixing.
Easy to react with thickener to meet thickening requirements.
It can cure quickly and improve production efficiency.
It has high thermal rigidity to ensure that the part will not be damaged when it is demolded.
It has sufficient toughness and does not crack when the workpiece is deformed.
MDC Mould, as a leading SMC mold maker in china, has developed such compression mold using low density SMC material, and finally testing was successful. Due to this, MDC Mould has been officially qualified by OEMS such as Daimler and Audi.
Manufacturing carbon fiber composites using SMC molds is one of the common methods in modern industrial manufacturing. The advantage of this method is that it can produce a large number of high-precision, high-quality carbon fiber composite products.
Carbon fiber composite materials are composed of composite materials such as carbon fibers and resins, and have the advantages of light weight, high strength, good rigidity, and corrosion resistance. Due to these characteristics, carbon fiber composite materials have been widely used in aviation, automobiles, sporting goods, construction and other fields.
In the automotive industry, carbon fiber composite products can replace traditional steel and aluminum products, which can reduce vehicle weight and improve fuel efficiency and vehicle performance. In the field of aviation, carbon fiber composite products can also reduce the weight of aircraft, improve fuel efficiency and flight performance. At the same time, carbon fiber composite materials are also widely used in sporting goods, such as golf clubs, bicycles, skateboards, etc., because of their light weight and good strength, they can improve the performance of athletes.
The SMC mold adopts the “SMC compression molding processing” production process. SMC, or Sheet Molding Compound, is a prefabricated composite material, usually composed of carbon fibers, resins, fillers, and additives.
The use of SMC molds in the production of carbon fiber composite materials offers several advantages over other manufacturing methods. These advantages include:
1. High precision and accuracy: SMC molds allow for the production of high-precision, high-quality carbon fiber composite products with consistent dimensions and shapes. This ensures that the final products are of the highest quality and are highly accurate.
2. High production efficiency: SMC molds can be used to mass-produce carbon fiber composite products with high efficiency. This can significantly reduce production costs and increase productivity.
3. High-quality finish: Carbon fiber composite products manufactured using SMC molds have a smooth, high-quality finish. This reduces the risk of deformation and cracking and ensures the durability and stability of the final product.
4. Design flexibility: SMC molds can be customized to meet specific design requirements, enabling the production of carbon fiber composite products of different shapes and sizes.
In conclusion, the use of SMC molds in the production of carbon fiber composite materials is a highly efficient, accurate, and cost-effective method. As carbon fiber composite materials become increasingly popular in a wide range of industries, the importance of SMC molds will only continue to grow. Future advancements in SMC mold manufacturing technology will undoubtedly lead to even more efficient, accurate, and high-quality production of carbon fiber composite materials.
MDC Mould focuses on composite material molds and compression molds, and is a very professional and well-known SMC mold manufacturer at home and abroad. The company has mature and complete development capabilities. As a local manufacturer of hot-pressing molds in China, the molds manufactured by the company can fully meet the quality requirements of the world’s top 500 companies, and its technology has reached the international level.
MDC Mould is a professional mold manufacturer, which is famous for its excellent technology and high-quality products,.
The design and manufacturing quality of the mold directly affects the quality and performance of the final product. For example, in aircraft manufacturing, it is necessary to manufacture a large number of products with complex shapes, so SMC molds with high precision, high stability and high efficiency are required. Only in this way can the needs of aircraft manufacturing be met, and the quality and safety of products can be guaranteed.
SMC mould
MDC Mould is a professional mold manufacturer, famous for its excellent technology and high-quality products. The company has a skilled and experienced R&D team, as well as a group of high-quality production workers, committed to providing customers with the best quality mold solutions. Whether you need mold design, manufacturing, or processing to after-sales service, MDC Mould always takes customer satisfaction as the highest goal, adhering to the corporate philosophy of “quality first, integrity first“, constantly pursuing excellence and innovation, and winning the trust of customers and praise. It is acknowledged that MDC Mould is a trustworthy enterprise. Its technical strength and quality assurance make it stand out in the industry and become the preferred partner of many customers.
the advantages of using SMC molds to manufacture aircraft components
In recent years, the use of composite materials in commercial aviation aircraft has increased significantly and has become a pillar material in the aviation field. According to the forecast of the International Air Transport Association (IATA), the demand for composite materials in the global air transport industry will increase to $600 billion in the next 20 years, accounting for more than 70% of the total demand.
Among them, SMC molds can manufacture complex and detailed parts with extremely high precision. In aircraft manufacturing, SMC molds are usually used to manufacture aircraft shells, bulkheads, interiors and other components.
One of the advantages of using SMC molds to manufacture aircraft components is that it can produce lightweight, strong, and corrosion-resistant parts. These characteristics are very important for aircraft because they can reduce the weight of the aircraft and improve its performance, thereby reducing fuel consumption and reducing carbon emissions. It can also extend the time of staying in the air, thus enabling the aircraft to fly higher and faster or have better maneuverability. At the same time, the aircraft can also install more equipment to improve the overall performance of the aircraft. Reducing the quality of the structure can greatly reduce the use cost of the aircraft and achieve obvious economic benefits.
On the other hand, SMC products also have high processing performance and can be made into various complex shapes and sizes, which can help designers realize their creativity and imagination.
MDC Mould is a professional and renowned mold manufacturer, especially specializing in SMC mold, BMC mold and other compression mold. If you have any need, please contact us at [email protected];
As a mold which is usually used in the manufacture of complex parts or products. SMC molds also play an important role in the aircraft manufacturing industry.
SMC mold is a mold used to manufacture complex shapes, usually used in the manufacture of complex parts or products. An airplane, on the other hand, is a complex mechanical device that requires many parts to build. Therefore, SMC molds also play an important role in the aircraft manufacturing industry.
It is calculated that nearly 10 tons of SMC materials used by BOEING 777 aircraft. The wings and empennage of the “Seasar” CD2 of Dornier Starfish Malaysia are made of SMC mold.
Boeing 777
Seastar
Here are some examples of using SMC products to manufacture aircraft parts:
1. Aircraft shell: large and complex shell parts, such as aircraft fuselage, wings, empennage, etc.
2. Bulkheads and interior trim: such as seats, cargo walls, toilet partitions, etc.
3. Engine cover: SMC molds have excellent heat resistance and flame retardancy, and are suitable for high temperature and high pressure environments.
4. Landing gear cover plate: SMC mold has the characteristics of high strength and light weight, which can improve the fuel efficiency and performance of the aircraft.
5. Auxiliary materials for aircraft parts: such as the skeleton of aircraft flaps, flap extension mechanisms, mounting brackets, etc. Although these parts are not directly exposed to the outside, they are also important components of the aircraft.
During the production of SMC molds, it is unavoidable to generate pollutants such as waste water and waste gas. The threat to the environment and human health caused by the discharge of these waste materials cannot be ignored. As a professional mold manufacturers, MDC Mould…
During the production of SMC molds, it is unavoidable to generate pollutants such as waste water and waste gas. The threat to the environment and human health caused by the discharge of these waste materials cannot be ignored. Therefore, it is necessary to carry out environmental protection technologies such as waste water treatment, waste gas treatment and resource recovery.
waste water treatment
Waste water treatment refers to a technology that removes or transforms harmful substances in waste water to meet discharge standards. During the production of SMC molds, the waste water mainly contains harmful substances such as resins, solid particles, chemicals, and oils. We have three ways. Physical treatment mainly uses filtration, precipitation, membrane separation and other methods to remove solid particles and grease in wastewater; chemical treatment mainly uses oxidation, reduction, precipitation and other methods to chemically transform harmful substances in wastewater; biological treatment mainly uses microorganisms to degrade and transform harmful substances in waste water. After it, the harmful substances in the wastewater are removed or transformed to meet the discharge standards required by environmental protection, which can reduce environmental pollution.
waste gas treatment
Exhaust gas treatment refers to a technology that removes or transforms harmful substances in exhaust gas to meet emission standards. During the production of SMC molds, the exhaust gas mainly contains harmful substances such as volatile organic compounds and nitrogen oxides. The methods of exhaust gas treatment also mainly include physical, chemical and biological treatment.
resource recovery
In addition to processing, we can also recycle useful substances in waste materials. In the production process of SMC molds, resins and solid particles in waste water can be recovered by precipitation, filtration and other methods; volatile organic compounds in waste gas can be recycled by pyrolysis and other methods, and resources such as heavy metals in waste water and waste gas can also be recovered. It can be recycled by physical and chemical treatment and other methods.
For SMC mold manufacturers, it is necessary to establish waste water treatment systems, waste gas treatment systems and resource recovery systems to promote the sustainable development of the mold industry.
In the process of continuous research and development of higher-quality, higher-tech molded SMC molds, MDC Mould also pays attention to environmental protection and contributes to sustainable development.
Metallography is an important branch of metal materials science, which can provide strong support for material design and performance optimization.Composite materials have an analysis method similar to metallography called tissue analysis.
Although composites and alloys are both composed of two or more materials, they differ in that composites are usually composed of different types of materials that combine to form a new material properties; alloys are composed of the same or different metal elements, and their composition can be adjusted to change their properties. But for the latter, usually there will be no obvious changes in material properties like composite materials.
Metallography is an important branch of metal materials science, also known as metal microhistology. Observing the microstructure of metal materials through a microscope reveals the properties and behavior of metal materials. Metallography has important application value in the preparation, processing and use of metal materials. Metallographic analysis can provide strong support for material design and performance optimization.
Composite materials have an analysis method similar to metallography called tissue analysis or composite microhistology. Similar to metallographic analysis, tissue analysis is to observe the microstructure of composite material samples through a microscope.
The key to high-end manufacturing lies in materials. That is to say, through tissue analysis, to study the internal structure of composite materials, so as to optimize the performance, in order to manufacture better molds.
For example, fillers can be used to increase some of the final physical or mechanical properties of the SMC mould. The most commonly used filler is calcium carbonate. Extracted from ground limestone, they reduce manufacturing costs, but in turn, they increase the specific gravity of the produced parts. Alumina can make SMC molds have good dielectric properties, while hollow glass microspheres can significantly reduce the specific gravity of SMC components.
MDC Mould has been concentrating on research of moulds for so many years. We have “State-of–the-art” equipment, leading edge technological process and our first-class employees guarantees delivery to our customers across the world with high quality mold and products.
New energy vehicles are the future development trend of the automobile industry. SMC molds provide important support and solutions for the manufacture and development of new energy vehicles.
In 2022, the world is still under the influence of the epidemic, and many industries are swaying in the wind and rain. Even if the economic conditions are down, there is one industry in the world that is growing rapidly, which is new energy vehicles. As consumers’ demands for environmental protection, energy saving, and intelligence continue to increase, new energy vehicles are the future development trend of the automotive industry. But while environmental benefits are a motivating factor for EV adoption, vehicle performance and technology are the main draw. The improved driving experience brought about by technological progress, design and styles are all key factors in the popularity of electric vehicles. Especially for ordinary people, the most important advantage of new energy vehicles is not environmental protection, but low travel costs, and electricity bills are much cheaper than fuel bills.
Compared with traditional metal materials, composite materials manufactured by SMC molds(sheet molding compound) have the following advantages:
1. Lightweight: Composite materials made by SMC molds are lighter than metal materials, which helps to reduce the weight of the vehicle and improve the mileage and energy-saving effect of new energy vehicles.
2. High strength: The composite material made by SMC mold has high strength and rigidity, which can improve the impact resistance and tensile resistance of the body, and improve the safety of the vehicle.
3. Corrosion resistance: The composite material made by SMC mold is not easy to be corroded, which can ensure the long-term stability of the body and components.
4. Good shapeability: SMC molds can produce complex body and component shapes, have better shape performance, and can meet the design requirements of new energy vehicles.
5. SMC molds can also realize automated production through digital manufacturing technology, improve production efficiency and quality, and realize intelligent manufacturing, which will help promote the modernization and intelligence of new energy vehicle manufacturing.
Therefore, SMC mold provides important support and solutions for the manufacture and development of new energy vehicles.
According to the statistics, China is already the world’s largest market for electric vehicles, and it also leads in terms of infrastructure. There is no doubt that China is ahead of the trend.
MDC Mould is a professional manufacturer of SMC mold and BMC mold. The molds developed by our company have high difficulty, long service life, short cycle time, reasonable price, prompt delivery and considerate service, and are favored by customers at home and abroad.
