Duroplast examples – from Baumgarten

Industry: Automotive industry / e-mobility

Special features:
+ High design freedom. Realization of complex geometries without
Machining (no complex machining and post-processing)
+ Thermoset materials that come into question have a particularly high
good performance-cost ratio compared to metallic solutions
+ Extremely good planarity and tolerance accuracy (depending on the geometry, the
Realization of tolerances in quality IT 8 to 10 possible).
+ substitutes an aluminum component that has to be elaborately machined from all sides.
+ Excellent mechanical properties. (Additional usability as
Structural component with integration of e.g. bushing-free screw-on elements)
+ Geometric stability even in operating condition (continuous operation in
environments and high temperatures e.g. 180 C)
+ No corrosion

Application: In this automatic transmission component, the four large holes form the seat and the functional surfaces of the valves. The valve block is used to realize the oil channels and acts as a receptacle for the electric actuators that switch the hydraulic circuits. The component is firmly mounted using a direct screw connection without screw sleeves.

Industry: Automotive industry

Special features:
+ Complex, highly fissured component geometry, realized by tooling.
+ Extremely good ratio between component costs and functionality
+ Flat flange surfaces implemented without reworking
+ substitutes an aluminum component that has to be elaborately machined from all sides.

Application: This component is used in an engine oil pump. It is installed in a die-cast aluminum housing. By turning the component around the bearing point (semicircle at the bottom left of the picture), the volume flow of the oil is regulated fully variably according to the load condition of the engine. The efficiency of a fully controlled pump is significantly higher than that of a permanently driven pump (the oil flow rate only corresponds to the required volume flow). of the required volume flow). This reduces fuel consumption and CO2 emissions.

Industry: Automotive industry

Special features:
+ Substitution of sintered steel
+ 70% of the component surface with 0° draft angle (thermoplastic and die-cast aluminum components generally always require a draft angle)
+ The two ground surfaces (gray) have a parallelism of 10 µm. (high precision part)

Application: The component contains the intake and delivery side and conveys the cooling medium. The impeller adjacent to this component, which conveys the cooling medium, is driven by an electric motor.
The electric motor is connected directly to the spiral housing component using a customer-specific plug collar.

Industry: Industrial application and automotive industry

Special features:
+ Very sophisticated heat exchanger technology with complex slide gate technology
+ Plug pin injection with different geometric variants. Realization of several variants in one master tool
+ Realization of tool-falling customer contact points without mechanical processing of the precise functional surfaces

Application: Is installed together with a plunger and a handle as a module in a gas-insulated switch cabinet. This module serves as a central switching element for medium-voltage voltages

Industry: Electrical industry

Special features:
+ very high durability
+ high dielectric strength of 33kV/mm
+ Realization of high strength and simultaneous electrically insulating lightweight construction

Application: The pump cover creates a flat functional surface for the vacuum pump and also contains the functional bearing of a pressure relief valve. The component is installed close to the motor (temperatures up to +160°C) and permanently in an oily environment. The cover is firmly mounted on the pump housing using a direct screw connection without screw sleeves.

Industry: Automotive industry

Special features:
+ Highly flat functional surface on the inside and at the same time a highly jagged outside with pronounced stiffening ribs.
+ Realization of the flatness of the component geometry using tools, without machining. 
+ Screw-on areas by means of direct screw connection (without sleeves)
+ System integration of various functions in one component