Quebec – January 27, 2009 – Camoplast, in collaboration with Bayer MaterialScience and KraussMaffei, has developed Camoplast Long Fiber (CLF™), a major innovation that makes it possible to produce large parts using the long fiber injection molding (LFI) process. The first application of the technology is the hull of a personal watercraft (PWC) that will hit the market in summer 2009.

Camoplast: Can do attitude
For decades, PWC hulls were manufactured from glass fiber reinforced polyester resin using the robotic shell molding (RSM™) process or the sheet molding compound (SMC) process. When a customer challenged Camoplast to produce a lighter, more efficient hull for a PWC, the company researched many technologies and materials, ultimately determining that advancing the LFI process to produce larger parts could meet the goals of the project. These included achieving a superior Class A finish, reducing part weight without sacrificing strength, and also keeping costs down.

In LFI, long glass fibers are injected along with polyurethane resin in a one-step process: A fiberglass chopper is attached to the polyurethane dispensing mixhead, which is attached to a robot. The robot is programmed to move over the open mold cavity while simultaneously dispensing both the long glass fibers and the polyurethane resin in an open-pour method. At the end of the pour, the mold is closed to form the part.

Initially, Camoplast was told it couldn’t be done. But that didn’t stop the company, which prides itself on setting and achieving challenging goals.

“Camoplast’s mission is to set a goal and take all the necessary steps to reach it, one at a time,” said Yves Carbonneau, engineering director, Camoplast.

Through seven years of research and innovation by Camoplast, working alongside material supplier Bayer MaterialScience, and plastics processing equipment manufacturer KraussMaffei, Camoplast was able to meet the challenging objective.

To help bring the process from concept to reality, Bayer MaterialScience developed a proprietary grade of its Baydur® STR 814 polyurethane system, which is marketed through BaySystems™, the umbrella brand for the global polyurethane systems operations of Bayer MaterialScience. This new grade features a 60-second open time (compared with a traditional open time of roughly 10 seconds), enabling the flow of the material and reinforcing glass into tight spaces, previously impossible, thereby making it possible to design-in strengthening ribs, etc. At the same time, KraussMaffei enhanced its proven LFI processing technology by nearly doubling the glass output capability from 180 grams/second to 300 grams/second, enabling the production of the highly reinforced structural parts. The custom polyurethane formulation, along with specially designed KraussMaffei processing machinery and additional Camoplast innovations, makes it possible to produce large parts, such as the 12-foot-by-3-foot PWC hull, that are strong yet lightweight.

The first application of Camoplast Long Fiber (CLF™) technology, a major innovation that makes it possible to produce large parts using the long fiber injection (LFI) process, is the hull of a personal watercraft (PWC) that will hit the market in summer 2009.

Camoplast reaped other benefits, as well, by switching to CLF™ and the Baydur® STR 814 system. Polyurethane is a more environmentally friendly alternative to other types of resins like polyester, which contains VOC-emitting styrene that is a hazard to both the environment and machine operators. In addition, using polyurethane and CLF™ allows for faster, more automated production and a smaller manufacturing footprint, which are advantages in both cost-effectiveness and safety.

“Because this particular customer and manufacturer of PWCs had used glass-reinforced polyester resin for years, initially there was skepticism that making such a big leap to a new material, polyurethane, and a new technology would result in high-performance and great aesthetics,” said Carbonneau. “But we knew that CLF™ would provide the complete solution we were looking for.”

Polyurethane is less dense than polyester, making it inherently lighter weight and thereby contributing to improved PWC acceleration. In fact, the hull produced with the CLF™ process weighs 25 percent less than the previous hull. Safety was also a consideration, according to Camoplast.

“The hull of a PWC is the largest and most vulnerable part of the vehicle. As it breaks over waves there is the chance that it could crack,” said Carbonneau. “The part must have the best structural and mechanical characteristics while remaining lightweight for high performance. By using a light material, the Baydur® STR 814 system, reinforced with molded-in ribs, we achieved the necessary strength to withstand big waves and other safety issues that are inherent with a PWC.”

The use of CLF™ and polyurethane, along with design guidance from KraussMaffei, enables Camoplast to use a nickel shell mold, which is less costly than the steel mold needed in the SMC process. Furthermore, by using in-mold coating technology, Camoplast is able to produce a painted, Class A surface right out of the mold, eliminating costly and time-consuming secondary painting operations.

“The innovative solution Camoplast developed, CLF™, is the most efficient way to achieve the company’s high performance and aesthetic goals for the PWC hull,” said Craig Snyder, market channel representative, Bayer MaterialScience LLC. “Because innovation is a key focus area for Bayer MaterialScience, naturally we’re pleased to play a role in a project that is the first of its kind in the industry.”

Because of the many advantages the CLF™ process and polyurethanes offer, Camoplast is already investigating utilizing the technology to produce other parts. “We are very enthusiastic about this innovative technology and look forward to applying it to other demanding applications that require large parts that are durable, lightweight and attractive,” Carbonneau concluded.

About Camoplast
Camoplast is a privately owned company that designs, develops and manufactures specialized components, sub-systems and assemblies for the world leading original equipment manufacturers (OEMs) of both on- and off-road vehicles since the early 1960s. Products include: rubber tracks, rubberized wheels, undercarriage systems, body dressing parts, under-the-hood plastic components and assemblies, molded skis, engine covers, thermal and air induction systems. Camoplast delivers these products to the assembly lines of the world leading OEMs in a variety of markets including automotive, agricultural, construction and industrial, defense, and powersports. The company operates manufacturing plants in Canada, the USA, Europe and Asia. In each location, the company is committed to be the best at satisfying customer needs.