JEC COMPOSITES MAGAZINE - Issue #51 - September 2009 - 16

COMPANIES COMPANIES significant developments are halogen-free materials for electrical applications, for which the V0 fire-retardant properties earned UL094 approval, and automotive applications for headlamps with antifogging properties at elevated temperatures. The M&M group recognized the advantages of getting into composite materials in the early 1980’s, which perhaps was a contributing factor in its rise to become the leading polymer composite player in India. Starting with electrical applications, the company enhanced its capabilities by widening its base to hand-layup applications for medical equipment, and RTM for railways, defence and other niche markets. Mahindra Composites was the first in India to set up an SMC machine 122 cm wide. It gained expertise in DMC and BMC (Bulk Moulding Compound) for compression and injection moulding applications in the 1990’s. The company is so secure in its expertise that it is aiming “to become the leading SMC component manufacturer and the most technologically advanced compound manufacturer”. It would also like “to change the product mix from compounds to components for a variety of sectors, preferably in niche segments.” Focus Winner of JEC Innovation Award for Transportation - Additional information about the company: Manufacturer of SMC & DMC compounds and compression moulded components. Hand lay-up and RTM moulder. - Description of the composite innovation: Single-piece front fender for the TVS KING three wheeler, produced by SMC compression moulding. It is the first time in India that SMC is used for an exterior auto rickshaw component. - Added-value provided by composite materials: The single-piece product geometry was not possible in any other process. The class A surface finish matches steel panels. The dent proof, non-rusting component is moulded using a single-shot SMC process. This product is stronger, paint- friendly, long- lasting and will not de-colour in comparison with a thermoplastic part. - Development and launching of the innovation: The part 3D surface data was provided by the customer, who required 5,000 components per month. The component was assembled on the vehicle and launched in November 2007. - Market potential: The product has a potential of at least 200,000 vehicles produced in India every year. - Key benefits of the innovation: The front fender combines the mouldability of plastics with the strength of sheet metal, while offering OEMs design freedom and reduced development time and cost. Rosy prospects India’s composite market is growing steadily at a much faster rate than its GDP opening up a tremendous growth , potential for Mahindra Composites. As we have already mentioned, the company is also aiming to capture new markets, and for that is relying both on its knowhow and on innovation. Needless to say, it is interested in the wind-energy sector, and has just developed a 1.5-metre-long rotor blade for small household wind turbines. This market is less spectacular than the one for giant wind turbines, but there are opportunities in rural areas, especially where access to the grid is difficult. A project for a rotor-blade plant is ongoing in the Chennai region. Mahindra Composites is also working on a filament-winding process to reinforce bamboo canes for use as cheap, lightweight housing materials. Here again, the company is applying composites to find practical solutions to concrete problems; in this case, the solution under consideration would allow a majority of people to have access to easy-to-build homes at a cost of only a few hundred euros. Only 5% of Mahindra Composites business is generated by its own projects; the other 95% is done as a subcontractor. The company has made it clear that its objective is to focus on developing its own projects, as it is doing in the pleasure-boat sector. To further its own development, Mahindra Composites does not rule out creating joint ventures, setting up partnerships or investing in acquisitions or technologies if necessary. Over and above its own organic growth, it remains open to all opportunities. More information: www.mahindracomposites.com Electrical applications account for 70% of the business of Mahindra Composites. 16 jec composites magazine / No51 September 2009

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JEC COMPOSITES MAGAZINE - Issue #51 - September 2009

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