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Advanced
Materials
engineered formulations
The starting point in a composite product design is specifying the functional requirements and economics. Sometimes a standard formulary is an easy fit – but in most cases customers stretch for more. Lighter, stronger, faster, fewer pieces, fire-retardant, larger, chemical resistant, glossier finish, lower cost – characteristics that will provide a competitive edge.
This is where having the industry leader in advanced materials on your team ups your game. MFG brings a deep bench of material engineers and a dedicated R&D lab to assist you in analyzing your design against the properties of various materials. From there we can recommend a material – either a standard chemistry, a proprietary MFG formula, or a custom solution – that will achieve your targets.
Recognized internationally for having influenced the industry with many material innovations – we invite you to see how MFG’s composites expertise might help advance your composites project.
Our supply base is made up of high quality well-known high performing industry suppliers, and includes strategic partnerships.
fibers & resins
A composite is a combination of materials that yield properties greater than the individual ingredients. One material is always a particulate or fiber (reinforcement) and the other a formable solid (matrix).
Plastic resins are the formable matrix within the composite. Virtually all of the physical properties (chemical, electrical, and thermal) are strongly influenced by the resin. Most resins used in composites are the thermosetting type – once formed they cannot be reformed, and they do not melt or flow. Thermoplastics are also used in lower temperature applications. Most often they are enhanced with synergistic organic and inorganic additives to provide additional functionality.
Fibers provide strength, dimensional stability and heat resistance. Additives are easily incorporated into resin systems to provide pigmentation, flame retardence, weather resistance, superior surface finish, low shrinkage and other desirable properties.
Final properties are determined by many factors including the type, amount, and composition of the resin systems and reinforcements. In addition, the use of additives can greatly affect the properties.
Outlined here is information on the various reinforcement and resin systems that are the building block elements for composites. You may find it helpful to download our Design Guide.
reinforcements
- Glass
- Carbon Fiber
- Aramid
- Natural Fibers
epoxy resins
Epoxies are best known for their excellent adhesion, chemical and heat resistance, mechanical properties, and outstanding electrical insulating properties. The chemical resistance of epoxies is excellent against basic solutions (best choice for brine tanks).
Epoxies are more expensive than polyesters, and cure times are longer, but their extended range of properties can make them the cost/performance choice for critical applications.
The epoxy resins are formed by a reaction of an epoxide (like epichlorohydrin) with a hardener or polyamine (like triethylenetetramine) that has tremendous cross-linking to create a very tough and yet stiff polymer. The viscosity of epoxies is another step higher than polyesters or vinyl esters. Most epoxies start in the range of 900 centipoise.
related processes
Related Applications
Automative
MFG’s association with composites for automobiles goes back to the 1950’s. In fact, MFG pioneered mass-production of fiberglass automobile panels with General Motors’ famous 1953 Corvette.
Today MFG is focused on leveraging the intrinsic qualities of composites for advanced structural and under-the-hood components. Our ability to develop advanced material formulas that meet specific objectives gives you access to cutting-edge technology on a flexible outsource basis.
Although many processes, namely SMC compression molding, are used for automotive parts – our proprietary PRIME process has become a standard for structural and quality-critical parts. Using pre-placed reinforcement and production innovations, PRIME produces lighter, more efficient parts.
As a longstanding partner to leaders in the automotive industry, MFG is resourced and staffed to meet the needs of manufacturers in the areas of quality assurance, JIT delivery and project management.
Value Added Services
- Weight/mass reduction (light weighting)
- Part consolidation
- Engineering and design support
- Best in class material innovation
- Prototyping
- Professional project management team
- Plants located across the USA and Mexico for JIT delivery and low transportation cost
- Material formulation
Under Hood Panels
- Cooling modules covers/panels
- Battery boxes/covers
- Engine covers (interior/exterior)
- Firewalls
Quality & Certifications
- ISO-9001
- IATF 16949:2016
- UL-recognized materials. For more info see UL file number E54325 and E76349.
Structural
- Load floors
- Dash panel assembly
- Lower plenum assembly
- Upper plenum assembly
- Surround (coupe and convertible)
- Wheelhouse assembly
- Rear compartment (underbody)
- Front fascia
- Tunnel closeout
Exterior Panels
- Tulip panels
Testimonials
Design Drives Process > Process Drives Cost
We Optimize Design & Process
We Optimize Design and Process to Increase Quality and Reduce Investment.
MFG provides valuable design services to help customers optimize composite designs and ultimately, save time and money. As a leading expert in the composite industry, we know first-hand that every composite design has its own unique set of characteristics and features.
Our design team is available to help clients identify unfavorable design features and optimize product design prior to production. Our creative design work can significantly increase quality and savings over the life of a program, and helps customers avoid unexpected, costly changes.
MFG's Team
Working with the MFG’s design and research teams in the early development process allows thorough evaluation for Design for Manufacturing & Assembly (DFMA) through the entire process flow: design, materials, tooling, molding, process, finite element analysis, manufacturing and quality.
We work collaboratively to evaluate designs and propose optimized solutions for ease and leaner manufacturing process flow.
Meet Our Design Team
Our Core Capabilities
With decades of diversified design experience, we have extensive experience with heavy truck, automotive, wind energy, solar, electrification, military, commercial and proprietary products.
We offer critical design support services for new customer development programs to help you with: feasibility & cost savings, conversion studies of metallic part/assemblies to composites, design for six sigma (DFSS) principals and GD&T, and tooling/mold design concepts for cost and process optimization.
Design study check list includes: Die-line’s, radii, draft angles, ribs, assembly split lines, shear edges, molded in features, thickness transitions, Class A IMC flow, mating components, GD&T-tolerance requirements, bond assembly sequencing, part nest ability studies for shipping, tooling impact on revisions, secondary processing flow optimization.
Design study check list includes: Die-line’s, radii, draft angles, ribs, assembly split lines, shear edges, molded in features, thickness transitions, Class A IMC flow, mating components, GD&T-tolerance requirements, bond assembly sequencing, part nest ability studies for shipping, tooling impact on revisions, secondary processing flow optimization.
Design study check list includes: Die-line’s, radii, draft angles, ribs, assembly split lines, shear edges, molded in features, thickness transitions, Class A IMC flow, mating components, GD&T-tolerance requirements, bond assembly sequencing, part nest ability studies for shipping, tooling impact on revisions, secondary processing flow optimization.
Design study check list includes: Die-line’s, radii, draft angles, ribs, assembly split lines, shear edges, molded in features, thickness transitions, Class A IMC flow, mating components, GD&T-tolerance requirements, bond assembly sequencing, part nest ability studies for shipping, tooling impact on revisions, secondary processing flow optimization.
Design study check list includes: Die-line’s, radii, draft angles, ribs, assembly split lines, shear edges, molded in features, thickness transitions, Class A IMC flow, mating components, GD&T-tolerance requirements, bond assembly sequencing, part nest ability studies for shipping, tooling impact on revisions, secondary processing flow optimization.
MFG Research & Test Lab
Material Development, Testing, Validation and Problem Solving
A distinction between MFG and other composite manufacturers is the support we provide customers through our dedicated R&D laboratory, MFG Research. It is in fact the largest and best-equipped in-house laboratory in the composites processing industry and can provide you with expertise in materials testing, material selection and process development, along with the ability to rigorously test and verify product integrity.
This resource translates to customer value:
- Accurate, fast-response technical and laboratory support that enables MFG to help you improve your products, accelerate development
cycle time and reduce fabrication costs. - Should problems arise while your product is actively in service, we can assist you with testing, analysis and remediation guidance.
- The lab is A2LA-Accredited, Certificate #1280.01. (see complete list for details).
- The lab has ISO/IEC 17025:2017 certification, the standard for Testing Competence of Laboratories.
- A la carte testing and validation services are available to support customers in the development or selection of materials or processes
for any composite product.
Download A2LA certificate and full scope of our accredited tests here.
