Automotive PU-SMC Bumper Beam Molding Line Project in China
Haifeng delivered a turnkey PU-SMC molding line for automotive bumper beams, achieving 40% weight reduction and a 2.5-minute demold cycle.
Project Overview
Illustration notice. Process illustrations are not verified photographs of this installation.
Project reference basis. Figures and configuration details are reported in the supplied project brief. They are reference values for the stated application, rather than verified acceptance results or a guarantee for another installation. Confirm the source records, material, tooling, operating schedule and test method when assessing a comparable project.
Haifeng engineered and commissioned a turnkey Polyurethane Sheet Molding Compound (PU-SMC) production line for an anonymized Tier-1 automotive composite supplier in China. The line produces front bumper beam components with 40% lower weight than the compared stamped steel assemblies. The delivery covered polyurethane metering, resin conditioning and interfaces for compression molding presses.
The customer sought lower component weight, shorter molding cycles and improved resistance to dynamic loading. The project targeted a 2.5-minute cure and demold cycle at a 130°C mold temperature, together with lower tooling expenditure than the referenced metal stamping dies.
Commissioned in September 2024, the line operates on two shifts per day within a 300 m² production area. Haifeng integrated metering, temperature control and press synchronization to support structural composite production and dimensional quality checks.
Planning a related production line
Use this record as an application-specific reference. Reinforcement introduction, resin chemistry, tooling, consolidation and qualification differ between RIM, LFI, SMC and HP-RTM. A result from one process does not establish performance of another.
Production brief for technical discussion
Provide a finished-product drawing or sample, material data, target output, automation needs and factory conditions. Haifeng will review the process, equipment interfaces and acceptance plan for your own production goals.
Concept illustration: The process image is a concept illustration used to explain the equipment arrangement; it does not document the delivered site.
Solutions Delivery
Haifeng supplied an automated PU-SMC metering and thermal conditioning system for the bumper beam molding line. The system coordinates polyurethane dosing, resin and mold temperature, compression press sequencing, safety controls and commissioning.
Closed-loop dosing and stream injection: conditioned polyol and isocyanate streams are metered to the specified ratio and delivered to the fiber impregnation stage.
Temperature control: resin circuits and the mold are controlled to support consistent material flow and the 130°C molding process.
Press synchronization: the dosing system interfaces with the hydraulic press for repeatable process sequencing, pressure control and cure execution.
Safety and quality: PLC controls monitor pressure and temperature deviations and manage purge and safety interlocks. Installation and commissioning took 14 days; operator training took 3 days. The delivered system carries a one-year warranty.
| Equipment | Model | Qty | Function |
|---|---|---|---|
| PU High-Pressure Metering Unit | HF-HP Series | 1 Unit | Ratio-controlled dosing of polyurethane resin components. |
| Dual-Circuit Temperature Controller | HF-TCU-48 | 2 Units | Temperature conditioning of resin tanks and piping. |
| Automated Resin-Fiber Impregnator | HF-MIX-SMC | 1 Set | Liquid stream delivery and wetting of the fiber reinforcement. |
| Master PLC System Cabinet | HF-PLC-V4 | 1 Set | Process sequencing, monitoring and press safety interlocks. |
Project Results
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