Injection Molding Thermoset for Automotive

As a performance grade composite, thermoset plastics are used in a variety of challenging automotive environments and applications. Thermosets provide excellent heat resistance and temperature deflection to avoid deforming or degradation when exposed to high operating temperatures. Utilizing an injection molding process with thermoset not only gives an automotive part the physical and durability properties, but provides a high-throughput option for high volume programs that require large outputs of product. Injection molding thermosets use faster cycle times than compression, and injection molds can built with higher cavitation as well. Automotive applications that rely on injection molded thermoset parts include powertrain and transmission parts that are in contact with automotive fluids and oils. Interior ash cups were once a high-demand component utilizing a thermoset injection molding process. With the increase and development of Electric Vehicles and electrification in vehicles, thermosets are a perfect match for electrical applications such as sensors, connectors, housings, as well as charging components.

Examples of thermoset materials used in injection molding applications include phenolic and bulk molding compound (BMC). Phenolics are injection molded with the use of a hopper, similar to thermoplastics whereas BMCs are molded using hydraulic stuffers. Cost-wise, thermosets such as Bulk Molding Compounds (BMCs) and Phenolics are priced competitively in the $1.00 – $3.50 range depending on commercial volume and formulation, allowing them to compete with advanced thermoplastics and metallic solutions at an advantageous price point for raw material.