Business Unit Thermoset Baypreg

Baypreg Mold

PU Sandwich Construction.
Ultra-Lightweight Load Floors & Structural Trim.

SANDWICH

The Sandwich Structure Advantage

Baypreg (PU Compression Molding) is a cutting-edge process for manufacturing lightweight sandwich composite parts. It typically involves a paper honeycomb core sandwiched between two layers of glass fiber mats and sprayed with a two-component polyurethane (PU) system.

At SUASE MOULD, we engineer specialized tooling for this low-pressure process. The result is a component with an exceptional stiffness-to-weight ratio, far superior to solid plastics or wood. This makes Baypreg the industry standard for automotive load floors and spare wheel covers.

Variable Thickness

"Our molds are designed to accommodate varying part thicknesses in a single shot, allowing for reinforced mounting points and thinner, lighter central areas."

Honeycomb Core Material
Honeycomb Core

The Manufacturing Process

Combining PU spray technology with precision compression.

1. PU Spraying

A robot sprays PU resin onto the glass fiber mats on both sides of the honeycomb core.

2. Transfer

The sprayed sandwich stack is transferred by robot into the heated SUASE mold.

3. Molding

The mold closes. The PU resin expands and cures, bonding the layers and forming the shape.

4. Demolding

The finished part is removed. Optional in-mold coating can provide decorative finishes.

Tooling Capabilities

Specialized molds for low-pressure applications.

Baypreg Mold Specs

Mold Material S50C / P20 Steel
Cutting Edge Pinch Edge (for fabric trimming)
Heating System Water / Oil (60°C - 80°C)
Ejection Air Blow / Mechanical
Cycle Time 60s - 120s

Extreme Lightweight

By using a honeycomb core, parts can achieve densities as low as 0.2-0.6 g/cm³, significantly lighter than solid SMC or thermoplastics.

High Stiffness

The sandwich construction provides excellent bending stiffness, making it perfect for load-bearing floors that must support heavy cargo.

Thickness Flexibility

Our molds can produce parts with variable thicknesses (e.g., compressed edges for mounting, thick centers for strength) in one operation.

Baypreg Applications

Load-bearing solutions for automotive interiors.

Load Floor

Trunk Load Floors

Adjustable cargo floors. High load capacity with minimal weight, often covered with carpet directly in the mold.

Spare Wheel Cover

Spare Wheel Covers

Covers that conceal the spare tire. Must be tough enough to support luggage but light enough for easy lifting.

Sunroof Shade

Sunroof Shades

Sliding shades for panoramic sunroofs. Requires perfect flatness and dimensional stability to prevent jamming.

Lightweighting Without Compromise

"SUASE's Baypreg tooling expertise helps automakers achieve their weight reduction goals. Let's discuss your sandwich molding project today."

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