Merriott Group Blog // Part 1: Thermoset Composites in Metal Replacement
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With the increasing demand for cost-effective, lightweight, and durable materials, thermoset composites have become an attractive alternative to metals in various industries. Thermoset composites provide a unique set of advantages over traditional metals, particularly in applications where weight reduction, chemical resistance, and strength are essential. But how do you determine if these materials are the best fit for metal replacement? In this blog, Merriott Group explores the advantages of thermoset composites as a metal replacement. The company delves into its cost-saving potential and examines how its material versatility can meet specific application requirements across various industries.
Thermoset composites offer significant cost savings compared to metals, especially when moulded into complex parts. These composites can incorporate threaded inserts either during moulding or as post-mould additions, which increases versatility and makes them suitable for a variety of industrial applications.
Thermoset composites can be colour-matched (depending on the material) and meet stringent manufacturing tolerances, making them an excellent choice for parts where consistent quality is crucial. By choosing thermoset composites, manufacturers can reduce material costs and avoid the complexities of metal die casting, all while retaining the strength required for demanding environments.
Another advantage of thermoset composites is their versatility in material selection. During the design phase, engineers can select from various composite materials to ensure a perfect fit for specific applications.
Available materials range from wood flour, glass, and mineral-filled phenolic compounds to glass-filled flame-retardant polyesters, Bulk Moulding Compounds (BMC), Dough Moulding Compounds (DMC), Sheet Moulding Compounds (SMC), and melamine. This selection process ensures that each component meets application-specific performance needs.
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