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We guide our customers to success through precision, expertise, and process know-how.
At Menzolit, we deliver process excellence beyond just materials. Our SMC and BMC compounding solutions are engineered to ensure the highest performance in strength, durability, and surface quality. From the first moulding trials to complete process optimisation, we partner with our customers at every step to deliver consistent, high-quality results.
Compression Moulding of SMC and BMC
Compression moulding of Menzolit SMC is the preferred method for producing high-performance parts with outstanding strength and surface finish. As an independent compounder with decades of experience, Menzolit supports customers from initial moulding trials to complete process optimisation.
Basic requirements for a successful moulding process
A successful compression moulding process begins with selecting the right equipment and maintaining precise control over every parameter. Menzolit recommends a press force of around 1000 tons per square metre of the moulded part, which can be reduced with low-pressure Menzolit SMC grades. Parallelism control helps to protect the mould and save material, for Class A surface quality it’s a must.
The design and construction of the mould is critical for achieving the correct part quality. Using steel moulds with a higher chrome content provides durability and dimensional stability, while integrating shear edges is essential for the moulding process. For reliable de-moulding, ejector pins and air valves are recommended to assist the release process and prevent damage or surface imperfections.
Temperature control is another essential factor. The mould heating system should maintain a heating capability of 130°C to 160°C for optimal curing and material flow. For Class A parts requiring a premium surface finish, a chrome-plated tool equipped with vacuum assistance ensures superior gloss and uniformity.
Cutting table, balance and fixtures adapted to work with SMC rolls, JumboRolls or boxes complete the production equipment requirements. Recommended are fixing rigs for deflashing or secondary operations like drilling as well as cooling racks for maintaining part dimensional accuracy. Almost complete automation of the process is possible. Ask us for more details
Compression moulding process steps
The compression moulding process is a carefully sequenced operation designed to deliver consistent quality and optimal performance. Each stage, from cutting to cooling, contributes to the final part’s uniformity, strength, and dimensional stability.
- Cutting Menzolit SMC charge The compound is cut into pre-measured charges to match the required part weight and shape, ensuring even material distribution during moulding.
- Placing SMC into the hot mould The prepared SMC charge is positioned accurately in the heated mould cavity to achieve optimal flow and uniform filling.
- Compression moulding under controlled pressure and temperature The mould closes and applies precise pressure and heat, allowing the material to flow, cure, and take the exact shape of the cavity.
- Demoulding Once curing is complete, the mould opens, and the finished part is released using ejector pins or air valves to prevent surface damage.
- Removal, deflashing, and cooling as required The part is removed, any excess material is trimmed or deflashed, and it is placed on cooling fixtures or racks to stabilise its dimensions.
“Precision, performance, and process reliability – every part begins with the right compound and the right expertise.”
Injection and Injection Compression
Injection moulding of Menzolit BMC and SMC delivers exceptional results for high-volume production, combining strength with tight dimensional tolerances. As with compression moulding, Menzolit’s team provides comprehensive support from process setup to fine-tuning to enhance efficiency and performance.
Basic requirements for a successful injection process
Injection machine
High-quality results start with specialised injection machines designed for BMC and SMC materials. These machines ensure optimal compound flow and consistent filling of the mould cavity. The compound is typically delivered through a screw-feed or plunger system into a liquid-tempered injection unit. In most cases, screws (charging-type without compression) are used and equipped with a check valve to maintain stable material delivery and prevent backflow during the injection cycle.
Mould
Menzolit recommends using steel moulds with high chrome content to ensure dimensional precision and long tool life. Additional chrome plating further enhances productivity and durability. Shear edges are recommended, and in any case essential for injection compression moulding, as they help control material flow and ensure uniform cavity filling.
Effective de-gassing, supported by ejector pins and optional vacuum systems, prevents air entrapment and surface defects. The mould’s heating capability should range from 130°C to 200°C, with control of ±3°C on the tool surface. Slides, cold runner and gate cutter systems are as usual as stamping of cores.
Peripheral Equipment
Robotic systems are commonly used for automated part removal and post-moulding operations such as deflashing, drilling, and machining. These systems help maintain part integrity while reducing manual handling and production time.
Automation
Complete automation of the process including post-moulding operations is possible. Fully automated workflows reduce cycle times, improve process consistency, and enhance overall operational efficiency. This level of integration transforms complex moulding sequences into streamlined, scalable production systems.
“From starting first moulding activities to optimizing your process - Menzolit will serve you with all the necassary support.”
More Resources
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