Baypreg Mold
PU Sandwich Construction.
Ultra-Lightweight Load Floors & Structural Trim.
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."
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.
Trunk Load Floors
Adjustable cargo floors. High load capacity with minimal weight, often covered with carpet directly in the mold.
Spare Wheel Covers
Covers that conceal the spare tire. Must be tough enough to support luggage but light enough for easy lifting.
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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