Baypreg® Compression Molding

The process involves spraying honeycomb boards and fiberglass with PU and pressing them together in a heated tool to complete the chemical reaction. This process allows us to manufacture light components with high load bearing capacity, high temperature resistance and dimensional stability.

By incorporating different types of honeycomb core with different glass density in our PU process, our team of experts develop solutions that maximize cargo space, functionality and performance while minimizing the mass.

Typical Applications include:

  • Cargo Covers
  • Load Floors
  • Seatbacks

ProBond™ (Wet Urethane)

Our exclusive ProBond™ process is mainly used for headliners and fixed package tray applications. It involves pouring PU chemical into a slab foam carrier and adding various layer of material such as: chopped fiberglass, fleece, adhesive and fabric. The uncured composite is placed into a heated tool and compressed into its final shape.

Our ProBond™ process is flexible enough so we can modify the construction to meet our customer particular requirements, providing high temperature resistance and exceptional dimensional stability.

Typical Applications include:

  • Headliners
  • Fixed Package Trays
Thermoforming

Thermoforming

The thermoforming process involves heating up a sheet or composite of thermoplastic material to a pliable temperature then mold to a specific shape.

SA Automotive thermoforming process expertise is in the following sub-processes:

  • Vacuum forming blow molding (twin sheets)
  • Compression molding single substrate
  • Compression molding composite

Typical Applications include:

  • Package Trays
  • Cargo Covers
  • Trunk Trim
  • Door Panel Components
  • Seatbacks
  • Headliners
  • Load Floors

Injection Molding

The injection molding process involves material such as synthetic resins (plastics) that are heated, melted and then sent to a mold where they are cooled to form a specific shape.

SA Automotive has ability to manufacture parts in presses that ranges from 500 tons to 3500 tons.

Typical Applications include:

  • Cargo Bins
  • Headliners
  • Cargo Frames
  • Side Trims
  • Back Injection
Machinery
Die Cut

Cutting / Trimming (Pinched Trim, By-Pass Die, Water Jet)

SA Automotive has the capacity to perform different cutting/trimming processes required for specific applications according to the part design.

Typical Applications include:

  • Spare Tire Covers
  • Headliners
  • Load Floors

Edge Wrapping / Lamination

The lamination and edge wrapping process involves bonding an aesthetic fabric or non woven material on a molded substrate. In many cases the covering material can be laminated in the molding stage but in some other cases, where the covering material needs to be wrapped around the substrate or needs to be removed from certain areas, a secondary lamination edge wrapping process is required.

Our knowledge in edge wrapping equipment design, various fabrics and adhesives along with our expertise in covering difficult contours and tight radii allow us to perform this process with a minimum amount of steps and rework.

Typical Applications include:

  • Package Trays
  • Cargo Covers
  • Door Panel Components
  • Seatbacks
  • Headliners
  • Load Floors
Edgewrap