Maximizing Precision and Performance in Aerospace with Advanced Molding Techniques
At Woodland Plastics, we’re always striving to deliver the most efficient and effective solutions for our customers in the aerospace industry. Aerospace manufacturers face unique challenges when it comes to producing lightweight, high-performance components that must withstand extreme environments. That’s why we rely on advanced molding technologies like Thermoset Injection Molding, Injection-Compression Molding, and Insert Molding to meet the demanding needs of aerospace production.
In this post, we’ll explore why these three molding techniques are game changers for aerospace applications and how they contribute to the next generation of aviation technology. (more…)
As a performance grade composite, thermoset plastic materials are used in a variety of challenging 
Whereas thermosets have long been a heavy used material within electrical housings, connectors, switches, relays, and circuit breakers, the increase in EVs have provided a new market for thermosets, but with similar environments to its industrial electrical counterparts. 
Thermoset plastics, or composites, differ from thermoplastic materials. While thermoplastics are more more common molding materials for general plastic use, thermosets are a material of choice for challenging applications exposed to electrical current, high temperature, or aggressive chemicals. In similar application settings, thermoplastics will degrade, jeopardizing the integrity of the molded part. Thermosets remain dimensionally and chemically stable within these elements. What materials are commonly used in thermoset molding? 
Thermosets, or thermoset composites, are molding materials specified towards a variety of home appliance products and applications. Thermoset materials including BMC and Phenolic are selected as a material of choice in these applications for their high heat and chemical resistance properties. Many home appliances and cookware products incorporate heating elements or electrical connections to power the products. 
Did you know that thermosets offer exceptional chemical resistance? Whether your application is exposed to solvents, acids, oils, automotive fluids, hydraulic fluids, or water/moisture or salt water run-off, thermoset parts remain strong, durable, and dimensionally stable throughout the life of the part, and do not degrade. This longevity makes thermosets a useful material choice for molding applications in automotive powertrain and transmission components, fuel system components, battery components, as well as appliance components and housings, industrial pump housings and pump components, and components used in the oil/gas industry. 
Why are thermosets commonly used as a molding material for electrical parts and component assemblies? Molded thermosets provide exceptional electrical properties such as electrical stability, high dielectric and insulation strength, and resistance to arc and track to protect internal components from potential damage caused by electrical charge or current and arc/track. 
Whereas a thermoplastic may degrade, disfigure, or ignite; thermosets such as unsaturated polyester BMC and phenolic molding compounds remain durable and strong when exposed to such electrical elements. From a cost comparison, thermosets are a great high volume commercial option available at a low cost per lb. compared to engineered thermoplastics with similar type of electrical and heat resistant properties. Common thermoset materials used in electrical applications include both phenolic and bulk molding compounds (BMC). 
BMCs, or Bulk Molding Compounds, are a type of thermoset material that are unsaturated polyesters or vinyl esters, and may be injection molded on horizontal molding machines. The properties of BMC molded parts exhibit exceptional dielectric strength, electrical insulation, heat resistance, and chemical resistance lending BMCs to be molded in a variety of safety-critical applications and component assemblies within the Electrical, Automotive, and Industrial markets. In its raw state, BMC resembles a play-dough like form and is filled with glass fibers or mineral fillers dispersed within the resin system to provide strength. Molding wise, BMCs are more commonly injection molded, but can also be compression or transfer molded. Injection molding BMCs require the use of a stuffer or ram to help inject material into the screw and barrel to preheat and plasticize prior to injecting into the molds. 
