Compression Molding of SMC (sheet molding compound)

This molding technique involves compressing material containing a temperature-activated catalyst in a heated
match metal die using a vertical press. The matched metal dies define the outer surface of the part being
made.

The molding process begins with the delivery of high viscosity uncured composite material to the mold. Mold
temperatures typically are in the range of 275- 350 Deg F. As the mold closes, composite viscosity is reduced
under the heat and pressure approximating 1000 psi. The resin and the isotropically distributed reinforcements
flow to fill the mold cavity.

While the mold remains closed, the thermoset material undergoes a chemical change (cure) that permanently
hardens it into the shape of the mold cavity. Mold closure times vary from 30 seconds up to several minutes
depending on part design and material formulation. When the mold is closed the pressure exerted by the press
tonnage forces the resin, gel coat and UV inhibitor throughout the reinforcement. The resulting part is
extremely strong, durable and consistent.

Advantages
Compression-molded box pads are twice as stiff as spray-up boxes. They are also superior in every
area of strength, offering 50-60% greater flexural strength, 20-30% greater tensile strength and 30-
70% greater impact strength than spray-up products.

Consistency-- wall thickness is consistent throughout the molded part, whereas sprayup construction
is difficult to control and is dependent on the operator.

UV Protection- Compression-molded box pads have integral molded U.V. protection throughout the
entire product; not just on the gel coat surface, which is the case with spray-up.

Speed of Production.

Class A Surface- Both inside and outside surfaces are smooth.

Disadvantages
High initial capital investment- match metal molds are very expensive thereby limiting compression
molding to only high-volume parts.

Spray-Up

Spray lay-up is an open mold process that uses mechanical spraying and chopping equipment for depositing
the resin and glass reinforcement. Chopping equipment consists of a spray gun attachment, which chops glass
fiber into predetermined lengths and projects it to merge with the resin mix stream. This causes the resin and
chopped glass to be deposited simultaneously to the desired layer thickness on the mold surface (or on the gel
coat that was applied to the mold.

The mold (female mold) is first coated with a wax to ensure removal after curing. A layer of gel coat is then
sprayed on to the mold to form the outermost surface of the products. The polyester resin is applied with a
spray gun that has a glass chopper attachment.

Layers are built up and rolled out on the mold as necessary to form the part. The spray gun has separate resin
and catalyst streams that mix as they exit the gun.

Drawing 1 - Spray Lay-up

Advantages
Low start up cost-- molds and equipment are relatively inexpensive.

Variable sizes-possible to modify mold sizes, thus enabling a wide range of available sizes.

Disadvantages
Only one side of the product is smooth.

UV protection and gel coat is only on the top surface.

Inconsistent product thickness--the product is only as good as the operator.

After manufacturing, part must be trimmed which leaves raw edges that are susceptible to
environmental ingress.

Conclusion

Each manufacturing technique has unique capabilities and limitations. Overall a compression-molded part is the
most desirable because you are guaranteed a consistently strong and durable product each and every time.
Unfortunately, for low-volume production, compression molding is not effective. Currently the spray-up process
is the best alternative for low-volume parts.

Compression Molded Spray-Up

Thickness Tolerance 1/1000th"=.001 1/16" to 1/4" Varies
25,000-30,000psi (ASTM-D790
Flexural Strength 17,000-18,000 psi
Test Method)
1.2-1.7psi x 106 (ASTM-D790
Flex Modulus .59-.65 psi x 106
Test Method)
12,000-13,000psi (ASTM-D638
Tensile Strength 9,100-10,500psi
Test Method)
Impact Strength 20-30 ft lbs/inch (ASTM-D256
15-17 ft lbs/inch
(Notched Izod) Test Method)
Glass Length (longer is
2"-3" Random 1" Random
stronger)
Glass Fiber Orientation Random Non-Random
Color Throughout Gelcoat surface only
UV Protection Throughout Gelcoat surface only
Resin Type Resilient Isophthalic Non-Isophthalic
Water Absorption Non-Existent 1.50%
Spalling, Chipping,
Rarely Variable
Splitting, Flaking
Blooming None Variable