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SMC and BMC in the automotive industry PDF Print E-mail
Composites are used in automotive and truck industry for over 50 years now.
Major reasons for automotive are weight reduction and design freedom as also cost competitiveness. SMC and BMC are widely used for exterior body panels. SMC and BMC are the best solution for weight reduction on a vehicle while stiffness or temperature performance or on-line paintability are basic demands and are also provided.
Examples are the decklids of various Coupés and Cabrioléts such as Renault Megane Coupe and Cabriolét, Ford Thunderbird and Volkswagen EOS.



The Thunderbird also has SMC fenders, hood and a tonneau cover made from SMC.
Since car bodies made of SMC / BMC have been realised (examples Chevrolet Corvette & Camaro, Renault Espace, Pontiac Fiero, GM Lumina APV and DC Viper, Renault Avantime, VOLVO ES 480) we can see structural components made of SMC coming up soon using the potential for more weight reduction.

In a project run by Menzolit and VW it was clearly demonstrated that an inner structure/ frame of a vehicle is feasable and can fulfil all requirements regarding stiffness and crash worthiness. A quarter body section with A and B pilar was made out of high performance compound (Menzolit-HPC) and moulded as two parts which were bond together with adhesive.
Newly designed Menzolit SMC 1800 is specialised to serve structural applications.



In the engine compartment SMC and BMC are used for oil sumps, valve covers and more and more for smaller precision devices such as throttle bodies and inlets.
Menzolit has specially designed materials for this use:

Menzolit SMC 1400
Menzolit BMC 1400

Lighting systems become very hot especially those which are encapsulated with a Polycarbonate window instead of glass.
Therefore many headlamp reflectors world wide are injection moulded from BMC. Menzolit offers special grades of SMC and BMC:

Menzolit BMC 3100

Features, Advantages and Benefits of SMC / BMC parts:

  • Perfect surface
  • On-line, in-line and off-line paintable
  • Parts integration
  • Light weight
  • Low system cost
  • Integration of functions
  • Easy to bond
  • Stiff
  • Good mouldability
  • Complex shape
  • Weathering resistance
  • Low moulding pressure
  • Low tooling cost
  • No corrosion
  • High stiffness & strength

Cost comparison of SMC versus sheet metal

Nowadays, car manufactures diversify their product portfolio significantly. Using the same platform with different body work leads often to annual number of vehicles between 30.000 and 100.000. Here MenzolitSMC offers not only weight savings but also – and that is even more important – a cost advantage.
Following we are showing a cost comparison of a tailgate made of Steel vs. SMC.
The tailgate is made from an inner support and an outer skin which are bond together and then painted. If the tailgate is made from sheet metal the aprts are welded sealed and corrosion protected before painting. To form these parts from metal 5 to 6 tools for the outer skin and further five for the inner shell are necessary. For SMC only one tool needed for inner and outer part for volumes up to 60.000 and 2 of each for twice the volume. Exceeding these numbers up to 80/160.000 an additional tool per shell is advised to have delivery security. With high volumes sheet metal is definite the more inexpensive alternative.

Cost comparison of tailgates made from sheet metal versus SMC





End of life of vehicle



The ELV regulation of the EU requires a detailed evaluation of parts used on the vehicle regarding ecological behaviour and recyclability.
Therefore a decklid concept was evaluated under the parameters of an eco balance and three models were compared to each other: aluminium, sheet metal and SMC.
SMC shows the best eco-efficiency.

eco efficiency analysis.pdf

To meet the demands for recycling the European Composite Recycling Company (ECRC) was established in Brussels to develop recycling solutions for composite parts.




Productlist

Product code Description


BMC 0390 Low Profile BMC with increased shrinkage compensation but reduced pigmentability. Shrinkage is approximately zero. Typical applications are functional compounds with light colours. Minimal fire retardancy UL 94 HB, higher retardancy upon request
BMC 0400 Low Profile material for Class-A body panel applications. The material provides an excellent surface for painted panels for the automotive industry.
BMC 0410 This product is recommended for components requiring very precise tolerances as an alternative to outsert technology. Ejector pins on male and female half of the mould are necessary.
BMC 1400 High strength material resistant to fuel, lubricants and cleaning agents being used around automotive engines. Examples are valve cover, carburettor housings.
BMC 3100 BMC for headlamp reflectors.


HPC 1200 High strength material with unidirectional reinforcement. Especially high strength and stiffness in direction of fibre orientation for structural applications.
HPC 1300 High strength material with unidirectional reinforcement. Especially high strength in fibre direction, high glass content.
SMC 0390 A product with improved surface quality if compared to SMC 0300. Pigmentable but not available in all colours. Typical applications are body panels for trucks, commercial vehicles or farm vehicles.
SMC 0400 Class-A SMC for exterior body applications on cars, LCV´s and trucks. These compounds mould to parts with good up to excellent surface quality for medium bake painted body panels.
SMC 0410 Premium Class-A SMC for on-line painted exterior body applications on cars developed with CCC technology. The parts have to be primed with a conductive primer before e-coating.
SMC 0412 Premium Class-A SMC for on-line painted conductive exterior body applications on cars. These compounds mould to parts with excellent surface quality and low surface conductivity for e-coating of on-line painted body panels. Therefore parts do not require .
SMC 0420 Low Density Premium Class-A SMC for exterior body applications on cars, LCV´s and trucks. These compounds mould to light weight parts with good up to excellent surface quality for low bake painted body panels.
SMC 0421 Low Density Premium Class-A SMC for on-line painted exterior body applications on cars. These compounds mould to light weight parts with excellent surface quality for on-line painted body panels. The parts have to be primed with a conductive primer before.
SMC 0430 Low Emission Class-A SMC for passenger cars. The parts have to be primed with a conductive primer before e-coating. The parts show low emission, low smell and low fogging.
SMC 0500 Low density SMC for non painted applications , density 1,5 kg/dm3
SMC 0520 Low density SMC for non painted applications. Density is below 1 Kg/dm3. Typical use is if thermal isolation or lowest weight are of importance.
SMC 1100 High strength material with chopped fibres and tough matrix resins for structural applications.
SMC 1400 High strength material resistant to fuel, lubricants,brake fluid and cleaning agents being used around automotive engines. Typical applications are oil pan or valve cover.
SMC 1500 SMC with high temperature stability for applications requiring high service temperature, for instance a heat shield.


New Developments / laboratory products


AdvancedSMC 0400 A new product based on unidirectional carbon fibres for lightweight class A automotive body panels.
AdvancedSMC 1300 A new product based on unidirectional carbon fibres for lightweight structural body panels.
CarbonSMC 0400 A new product based on chopped carbon fibres for light weight class A automotive body panels.
CarbonSMC 1100 A new product based on chopped carbon fibres for light weight structural body panels.
SMC 1800 Product for low weight design of structural applications. Strength , resistance to fatigue and dynamic loads is exceptional high.

 
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