Custom Molding with Thermoset Plastics at Work: Heavy Machinery Industry Edition

Custom thermoset plastic molding allows companies to convert heavy, dent-prone metal equipment parts to lightweight, impact-resistant alternatives, making it a useful solution for many industries. In the heavy machinery industry, equipment has a tough job to perform and regularly takes a serious beating. To meet that challenge, original equipment manufacturers (OEMs) and Osborne engineers put their heads together to create products with the durability to get the job done.

Why Choose Plastic Molding?

Plastic molding allows a versatility that most metals just can’t provide, offering flexibility in size, shape, and performance characteristics. By choosing the ideal plastic material or composite, along with the molding process that best fits the project, clients can control the part’s corrosion resistance, stiffness, impact strength, and heat or flame resistance.

Plastic can also be an economical option. Switching sheet metal equipment components to thermoset plastics can reduce the number of parts for a product and simplify installation. Less labor results in savings, and the plastic’s longevity decreases replacement costs and lost productivity due to repairs.

Heavy Machinery Thermoset Plastic Applications

For more than 50 years, Osborne has helped companies in the heavy machinery industry meet their most complicated equipment needs with custom plastic products. Molding services at Osborne include resin transfer molding (RTM) and reaction injection molding (RIM), including RIM molding with highly engineered materials like polydicyclopentadiene (pDCPD). Osborne also offers value-added turnkey solutions with a variety of support services, which include CNC machining and metal fabrication..

Here are a few parts molded at Osborne that are used by the heavy machinery industry:

Aerial Lift Platforms (Aerial Lift Buckets)

Used by companies who manufacture equipment that elevates workers for electrical line maintenance, tree trimming, and more.

• Material: Fiberglass reinforced polymer (FRP) composite, which reduces a bucket’s weight by 30% and increases its strength by 200% (compared to steel alternatives).
• Process: RTM, which allows color customization of the buckets and a matching in-mold gel coat. Ribs and skids are also molded in for support.
• Additional service: Brackets are added, mounting holes are drilled and steps are structurally bonded to the buckets.

Portable Lighting Equipment Enclosures

Used by sports organizations, municipalities, emergency personnel, and others to supply temporary, supplemental lighting. Osborne has manufactured doors for the lighting equipment’s electronics housing.

• Material: Telene^® pDCPD instead of steel doors that are prone to rusting and denting, this plastic also provides impact and corrosion resistance, as well as thermal stability in hot or cold weather. Choosing pDCPD increases a door’s paint adhesion and reduces the number of parts it requires.
• Process: RIM, which provides more aesthetic benefits along with the ability to incorporate additives for specialized resin formulations.

Concrete Truck Fenders

Mounted over the wheels of concrete trucks and other heavy vehicles to provide housing for taillights and prevent the wheels from throwing water or debris.

• Material: Hybrid polyurethane and/or DCPD, determined to be the best option by extensive finite element analysis. Both materials are flexible yet strong, and better able to withstand the violent vibrations and impacts that made metal fenders break down.
• Process: RIM, which provides the ability to add conduit inside the molded fender for easy installation of tail light wiring.
• Additional service: Holes for taillights are drilled.

Every part molded at Osborne is subjected to intense quality-control inspection before, during, and after molding, per company policy. This careful oversight has not only earned Osborne ISO certification, but thousands of satisfied customers all over the world.

Wondering if a custom-molded plastic product might be right for your equipment? Give us a call at 1-800-255-0316 or fill out our online form to speak with a qualified Osborne specialist.

This is part of a series about thermoset plastic applications in various industries. Learn how custom plastic molding benefits the military (link coming soon), agriculture and chemical manufacturing industries as well.