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Molded Fiber Glass

Companies
Molding the future through focused diversity

Founded 1948
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Corporate History and

Overview
• Family Owned since 1948
• 60 Years of Dedicated Composites Manufacturing
• Senior Management Team with Over 500 Years of
Composites Experience
• 15 Entities in NAFTA
• 2.0 Million Square Feet
• 2,000 Teammates
• Strong Balance Sheet
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History
1948 Premier Molding – Ashtabula, OH
1952 Tray Company – Linesville, PA
1955 Union City – Union City, PA
1956 Research Company – Ashtabula, OH

Growth
1962 Construction Products – Union City, PA
1979 Composite Systems – Ashtabula, OH
1985 West – Adelanto, CA

History
1994 North Carolina – Morganton, NC
1995 Northwest – Stevenson, WA
1997 Texas – Gainesville, TX
1998 Water Treatment Products – Union City, PA
1999 Kansas – Independence, KS
2003 Galileo – Reno, NV
2005 Alabama – Opp, AL
2006 Design Center – Portland, OR
2007 Mexico – Monterrey
2008 Wind Energy Services – Sweetwater, TX
2008 South Dakota – Aberdeen, SD
2009 Wind Energy Services – Independence, KS
2009 Wind Energy Services - Worthington, MN
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Two Watershed Events

1953 Corvette
MFG began production of all
the body panels for the
Corvette.
– Continuous Corvette
supplier including the
present C6 Model
– Robert S. Morrison –
Corvette Hall of Fame

1955 MFG Boat

• During a slow period in
plant sales, MFG
prototyped and built the first
fiberglass boats on the
market. When no other boat
builder had faith in FRP,
MFG started their own
company.
 1950s

1949 – Wonder bread trays 1954 – Chevrolet Corvette 1955 – FRP Boats

1960s

1961 – Truck Liners 1967 – Hoppers 1968 – Gamefisher Boats

 1970s

1971 – Washington DC Subway 1976 – Costa Mesa 1977 – Outboard Motors

1980s

1982 – Bob Evans Fascia 1980s – New Holland 1980s – Kenworth

1990s

1990s – Weinermobile 1996 – MiraVista™ Shakes 1990s – Freightliner

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2000 and Beyond

2001 – 34.5m blade 2002 – Avalanche 2003 – Shipboard Radome

2004 – Bridge Beams 2005 – Antennas 2005 – Personal Watercraft

2006 – Corvette Z06 2006 – Nissan 2007 – MRAP

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MFG
Business Segments
Proprietary
Military
• Water Treatment
Proprietary 5% • Construction
12% Wind
• Military/Government
33%•
Anti-Ballistics
Auto • Communications
14% • Trays/Pans/Boxes
• Fume Hoods
• Flat Sheet

OEM Truck
16% 20%

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 Corporate wide Composites Expertise
MANUFACTURING PROCESSES
RAW MATERIALS • Hand Layup
• Matrix • Sprayup
• Thermoset • Robotic Gel Coating
• DCPD (Metton) • Advanced Preform Process
• Polyester • Vacuum Infusion
• Vinylester • Vacuum Bag Molding
• Epoxy • Resin Transfer Molding Lite
• Phenolic
• SMC, LMC, CMC , BMC Compression
• Thermoplastic Molding
• LFT
• In Mold Coating (IMC)
• Reinforcement
• Bonding, Assembly and sequencing
• Glass fiber
• Robotic Routing and Water Jet
• Carbon fiber
• Aramid
• Finishing
• Sandwich Core • Paint Capabilities
Materials • Sandwich Core Composite Molding
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MFG Compression
Molding
 Hydraulic Press
Capacity
• CSC - 21 Presses
•75 to 3,000 Tons
• PMC - 22 Presses
•113 to 1,500 Tons MFG Enabling
• Tray - 24 Presses Technologies
 Automation / Robotics
•113 to 750 Tons
• Press
• NC - 4 Presses
•1,000 to 3,000 Tons Load/Unload
• Research - 3 presses • Preform
•up to 2,000 Tons • Resin Pour
• De Mexico - 2 presses • Waterjet
 Program Management
Program Management per QS9000 / TS16949
• Core Team(s) assigned - dedicated Program Manager
• Advanced Product Quality Planning (APQP)
• Product Design and Development
• Participate in Design FMEA
• Feasibility Reviews and Documentation
• Flow Diagrams
• Process Design and Development
– Control Plans, FMEA, Instructions and layouts
• Product and Process Validation – PPAP
• Project Timelines and review meetings
• Document Task Matrixes and responsibilities
• Interface with TMP to capture plant needs
• CATIA, Unigraphics and IGES Support
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MFG - Three Initiatives

 Dedicated Corporate Champion & Staff
 Management Educated in Lean and Six Sigma at All Entities
 Green & Black Belt Certification Program

Lean Six
Operational
Excellence

SENIOR
LEADER
MANAGERS
(SLM)
Pioneer SparkPlug
Technological Sales Growth &
Leadership Diversity
Research & Development  Decentralized sales structure
Materials supporting the diversity of MFG
 Processes  Identifies synergy among MFG
 Applications Entities
Commercialization  Leverages Lean 6 / Pioneer
 Sales / Marketing Benefits activities to develop new products
and markets
 Operational Improvements
MFG TRAY MFG NC (North Carolina)
Proprietary storage devices Heavy Truck Focus
APP robotic Preforming
Robotic resin dispense
Compression molding
SMC
LCM

In mold coating
Robotic WaterJet trimming
Robotic Adhesive Dispense
Robotic Routering
Part sequence control
Interior trim

MFG de Mexico MFG CSC(Composite Systems Co.)

QS 9000 Registered ISO 14001 Registered
Transportation and Lighting Freightliner Certified AIAG Affiliated
CFA Affiliated

Processes
Robotic Preforming (APP)
Robotic Resin Dispense
SMC Compounding
In Mold Coating
Compression Molding
SMC / LCM
Robotic Water Jet Routering
Prime and Topcoat Painting
Bonding and Part Assembly
MFG UC (Union City) MFG WTP
Heavy Truck and Custom Products Water Treatment Products

Processes
–Open Molding
–Robotic gel coating
–Robotic water jet
–Vacuum Infusion
–Prime Painting
–Bonding and Assembly

MFG CP (Construction Products) MFG Galileo

Concrete Forms Radomes and Antennas

Waffle Slab
Forms
Beam, Slab
Forms, Long
Forms
Round Column
Forms
Custom Forms
Special Shapes
MFG West MFG Texas
Wind Energy and Custom Wind Energy
Vacuum Infusion
Resin Transfer Molding (RTM)
Hand Layup
Sprayup

MFG South Dakota MFG Alabama

Wind Energy
Wind Energy
MFG WES Wind Energy Service
MFG WES Wind Energy
Service
Independence, KS Sweetwater, TX.

MFG WES Wind Energy

Service
Worthington, MN
MFG Design Center MFG Research
The MFG Design Center provides Certifications
various levels of design engineering
support to MFG Entities and •A2LA
Customers. •ISO/IEC 17025
•Freightliner
•General Motors

Composite Testing
•Mechanical Properties
•Physical Properties
•Bond Strengths
•Paint Adhesion
•Residual Styrene

Analytical
•Gas
Chromatograph
•Burnouts
•Surface
Contamination
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Anti-Ballistic Panels
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Military
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Alternative Energy
• Wind Energy

• Solar Energy
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Infrastructure

• Water Treatment

• Construction
Waffle Slab Forms
Beam, Slab
Forms, Long
Forms
Round Column
Forms
Custom Forms
Special Shapes
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Communications
• Radomes

• Antennas
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Rail Transportation
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Features & Benefits of SMC Compression Molding
• Sheet Molding Compound (SMC)- a Molding Compound Consisting of a B-staged Resin and Chopped
• Glass Fiber, Used in Compression Molding.
Utilizes coupled flow of chopped glass and resin resulting in consistent fiber content throughout the part.
• Pre-combined glass fibers flow easily for facilitation of more complex parts. Parts which could feature
Ribs, Bosses, Molded in Studs.

Cutting and Bundling Charge SMC Charge in Female Die Hydraulic Press utilized in
Compression Molding.

Mold Fully Closed- Material Flows

and Fills Tool, Producing Part. Molded SMC Shower Base
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SMC Production
“Best-in-Class”

Industry benchmarking
MFG CSC Ashtabula OH
MFG Premier Ashtabula OH
MFG Linesville PA
MFG Morganton NC
CSP Conneaut OH
IDI Noblesville IN
Budd Van Wert OH
Meridian Jackson OH

Supplier participation
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SMC Production
“Best-in-Class”

Processing upgrades
Capacity expansion
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Some Applications in SMC

• Fiberglass residential door skins

• Residential shower, sink, bath components

• Underground Transformer Boxes

• Truck body components

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Features & Benefits of LCM Compression Molding
“World leader”
• Liquid Composite Molding- a Closed Mold, Usually of Steel, Used to Form a Composite
Under Heat and Pressure.
• Utilizes “Positive Placed Glass” pre-form resulting in greater control of fiber orientation.
• Allows design tailoring to give additional strength to specific areas of a part.

Screen created in part Oven cures preform

shape with perforated metal and is removed from
screen

Binder and glass roving Vacuum behind screen

chopped to desired lengths draws and disperses
and blown toward screen glass into part shape
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Features & Benefits of LCM Compression Molding
“World leader”
• Lower molding pressure required than with SMC.
• Produces lower density part versus SMC given identical part thickness.
• Superior surface quality to SMC

Press applies
pressure to push
mix through glass
and cure
Resin and
fillers combined
on site to
create mix
Preform with mix
and veil
(if needed) are
placed on mold

Mix applied
to preform
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Some Applications in LCM

• Heavy Truck body panels

• Automobile Rear Compartment

• Safety Helmets

• Transit Seating
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Secondary Assembly Operations

• Value Add processes
– Robotic Machining – Bond of parts
– Water Jet Fabrication • Hand apply
– Drill fixtures • Robotic bond
– Peening – Hardware addition
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Research and Development

• Materials
– Industry standard materials
– Cutting edge developments
– Weight reduction case studies
• Process
– Selection guidelines
• Design education for engineers
– DFMA
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Nanoclay SMC and LCM

• Developed a process to exfoliate nanoclay filler in SMC and LCM paste

• Conducted production scale compounding and molding trials
• Test results confirm the following benefits:
- increased physical properties over standard SMC and LCM
- specific gravity reduction by 20% without glass microspheres
- enhanced pigmentation and appearance
- enhanced rheological behavior, improved mold flow properties
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High-Temperature Resistant
Laminate
• Epoxy based composites with Tg > 200 C ( 400 F )
• Polyester based composite with Tg > 375 C ( 700 F )
• Application is lead free solder pallet for the PCB market
• 65 – 70 % glass content = extremely high physical properties
• Close tolerance molding for flatness : 4 ft. X 8 ft. panel X 8 mm
thickness molding held to +/- 0.010” flatness, final surface
machining to a flatness of +/- 0.003”

Comparison of Tan Delta Rochling, Norplex Micarta, & MFG Epoxy Materials

0.42
Roschling Tan Delta Sample 1 Cycle2
0.4
Roschling Tan Delta Sample 2 Cycle2
0.38
WavMax 7000 Black Roschling Tan Delta Sample 3 Cycle2
0.36 WavMax 7000 Black Tan Delta Sample 1 Cycle 2
0.34 WavMax 7000 Black Tan Delta Sample 2 Cycle 2

0.32 WAV 06 Tan Delta Sample 1 Cycle 2

0.3 WAV 06 Tan Delta Sample 2 Cycle 2

WAV 06 Tan Delta Sample 3 Cycle 2
0.28
Rochling Epoxy
MFG Non-Epoxy System
0.26
0.24
Tan Delta

0.22
0.2
MFG Epoxy WAV
0.18 06
0.16
0.14 MFG Non-Epoxy
0.12
0.1
0.08
0.06
0.04
0.02
0
0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360 375 390 405 420
Temperature Degree C
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PP Honeycomb /
Fiber Glass TP Skins
• Developed a thermocompression process to fuse glass fiber
reinforced polypropylene skins to a polypropylene honeycomb
core
• Benefits include :
- ultra-lightweight laminate ( specific gravity = 0.235 g/cc )
- high stiffness – to – weight ratio
- high impact and damage resistance
- impervious to water and other environmental contaminants
• Target market is the food handling industry
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UV Stable SMC
• SMC formulations have been developed and tested that exhibit
< 30% loss in 60 degree gloss and < 1.0 delta E color change
after 1000 hours QUV bulb A exposure; goal of 2000 hours is
achievable
• Evaluating a black pigmented, low-profile, automotive SMC at
35 and 50% glass content that has demonstrated NO change in
60 degree gloss or appearance after 4000 hours of Xenon arc
exposure and 4 years of south Florida and Arizona test site
exposure
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Cored Phenolic Skin

Laminates
• Composites based on end grain balsa cores or syntactic foam
with glass fiber reinforced phenolic skins
• Composites based on phenolic resin impregnated Parabeam
fiber glass
• Defined benefits :
- high stiffness – to – weight ratio
- high resistance to fire environment
ASTM E-162-02a flame spread < 5
- low smoke and toxicity
ASTM E-662 optical smoke density < 40
• Target market is mass transit flooring
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Pigmented BC / CC IMC
Development
• Dual path development project with Sherwin-Williams and
OMNOVA
• Successful pigmented BC IMC trials conducted at MFG/NC on
M2 Hood and Undercab Cover
• Demonstrated successful pigmented BC IMC repair process
• S-W Approach : BC IMC with CC hand pour applied
• OMVONA Approach : BC IMC with CC IMC, initiated a 1 year
process development project to define a robust process
• MFG believes that IMC of BC and CC is feasible and only
realistic approach to pigmented IMC
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Carbon Fiber Laminates

• MFG continues to manufacture and mold standard density and
low density CF molding compound for Corvette applications :
- low density CFMC wheelhouse outer panel
- standard density skins on balsa cores for the floorboards
• Supply of CF is tight ; cost of CF is escalating
• Seeking new sources of CF to assure supply and stabilize
pricing
• Investigating a new wet slurry process for the preparation of CF
preforms for LCM molding based upon papermaking process
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Ballistic and Blast Resistant

Laminates
• Continuing development in high glass content ballistic resistant
laminates for vehicle armoring, architectural uses, and blast
resistant applications
• Laminates capable of meeting UL 752 Level 3 ballistic
performance have been demonstrated at 0.50” thickness and
5.0 lbs/ft2 areal density
• As a component of a complex, multi-material armoring system,
structure has demonstrated the ability to contain multiple hits
from a 50 caliber API round at 2750 ft/sec velocity
• Producing a blast mitigating footware device for defeating the
harmful personal effects of land mine detonations
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MFG West Coast Design Center
Value by Design… The MFG Design Center based in Portland, Oregon provides various
levels of design engineering support to MFG Entities and Customers.

Design Drives Process!

Process Drives Cost!
Optimization of Design and Process Through DFMA
Delivers Higher Quality Products and Reduces Overall
Investment!

CATIA V4 & V5 Cad Systems

(Advanced Solid/Surface Design & Detail)

Data Conversion for IGS, STP, DXF etc..

 Online Web-Design reviews

(Go-To-Meeting)

 Reverse Engineering Projects

DFMA (Design for Manufacture and Assembly)

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MFG-DFMA SMC/LCM Design Buy-Off

(Design features that require DFMA optimization)

 Die-Pull Studies, Block Studies  Draft Angles

 Bond Gaps, Stops & Overlaps  Over Sized Routed-Out Openings

 Holes & Slots- Molded, Drilled  Molded-In Features

 Shear-Edge Design
 Mold Scribes (Advantages)
 Minimum Radii
 Ribs, Bosses & Inserts
 Part Nestability for Shipping
 Material Thickness &Transitions

 GD&T and Process Capability  Check Fixture Requirements

 Tooling Impact (Engineering Changes)

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MFG Research
Established 1956
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40 Testing Accreditations

• Mechanical, physical, environmental,

flammability, electrical and chemical properties
• Thermal analysis
• FTIR (Fourier TransForm Infrared
Spectrometer)
• Dielectric analysis
• Optical microscopy
• In-house, professional engineers
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MFG Research
• A 60-year Track Record of Breakthrough R&D and Problem Solving At MFG,
technology improvement is an integral part of our business model. MFG Research is
the largest and best-equipped laboratory in the composite processing industry. It's
purpose is to provide MFG entities with accurate, fast-response technical and
laboratory support. This dedicated resource enables MFG to help customers improve
their products by leveraging the intrinsic characteristics of molded fiber glass
technology to improve performance, appearance, durability, electrical and/or
mechanical properties, development time cycle, as well as cost.

• The close working relationship between MFG Research and the MFG entities has
resulted in the development of many advanced material formulations and processes,
including our Automated Preform Process (APP) that elevates preform technology
into a new level of process superiority.

• MFG Research is certified via A2LA as an accredited laboratory per ISO/IEC 17025,
which includes 40 testing accreditations.
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Markets
MFG • Electrical

Business Segments •
•
Business Machines
Agriculture
T ru c k P ro p rie ta ry • Seating
• Water Treatment
21% 13% • Construction
• Lighting
• Wind Energy
• Rail
• Truck
• Specialty Automotive
• Aerospace
o • Military/Government
• Marine
W in d • Recreation
OEM 34% •
•
Communications
Residential
17% • Trays/Pans/Boxes
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