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Multitec® sprayable polyurethane systems have proven their value
Multitec® sprayable polyurethane systems have demonstrated their effectiveness in high-performance, environmentally friendly, and cost-efficient production. Developed by Bayer MaterialScience in Leverkusen, the Multitec® polyurethane spray system is a prime example of how economic and ecological development can go hand in hand. This liquid system, which can be used with or without glass fiber reinforcement, is ideal for creating parts with complex geometries using open or closed molds. The process is highly efficient, offering a curing time of just 3 to 5 minutes, significantly boosting productivity compared to traditional manual lamination techniques. It also eliminates the use of styrene and avoids energy-intensive post-curing steps.
Depending on the application, multiple spray operations can be performed sequentially, either with or without glass fiber reinforcement, to enhance strength or create a surface that's ready for coating. These advantages have been widely adopted in various industries. For instance, Pronar Sp. z o.o., a Polish agricultural machinery manufacturer, uses Multitec®-reinforced ABS to produce a complex-shaped hood for new tractors. Dr. Marc Schütze, an expert at Bayer MaterialScience, remarked, “This example shows how polyurethane spray systems can be used to manufacture high-quality parts for commercial vehicles.â€
Another application of the glass-reinforced Multitec® staple fiber spray system is found in Neoplan vehicles, where it is used to produce anti-drilling molded parts measuring 130 x 95 cm. These lightweight components effectively protect the upper oil pan from debris and rotating particles. In the bathroom industry, the Multitec® system has replaced traditional methods of reinforcing thermoformed PMMA or ABS films. Previously, this involved labor-intensive and energy-heavy processes, but the polyurethane spray system offers fast curing, no styrene usage, and excellent adhesion to film substrates. Bayer is currently developing a new foaming system to expand its capabilities further.
BaySystems® was introduced in March 2007 as the main brand under which Bayer MaterialScience consolidated its global polyurethane systems business. This rebranding affected existing product lines such as Baydur® and impacted the global network of polyurethane companies. More information about BaySystems® is available on their official website.
Bayer MaterialScience is one of the world’s leading polymer producers, with annual sales exceeding €10.16 billion in 2006 (excluding HC Stark and Wolff Walsrode). Its primary focus areas include the production of high-tech polymer materials and the development of innovative solutions for everyday products. Key industries served by the company include automotive, electrical engineering, construction, sports, and leisure. As of the end of 2006, the company operated 30 production sites worldwide with over 14,900 employees and is part of the Bayer Group.
In another breakthrough, the Baypreg® polyurethane spray system has revolutionized composite design by producing lightweight, high-rigidity molded parts. This sandwich component is not only light and shock-resistant but also rigid, making it ideal for sports equipment like skis and snowboards. According to Dr. Marc Schütze, Baypreg® is a viable alternative to traditional epoxy resins, offering resistance to styrene and compatibility with various core materials, including honeycomb structures. It can also be combined with different reinforcing fibers, ensuring full wetting and saturation of the material.
The Baypreg® system is especially useful in the production of skis and snowboards, where it allows for the integration of decorative surface materials. It also enables the creation of high-quality, non-decorative parts such as motorhome and caravan pedals. A notable example is the double pedal produced by Rapido camping car manufacturer Formtec PUR Verarbeitungs GmbH in Germany, which features a natural fiber outer layer and a polyurethane core.
In the realm of safety, glass fiber reinforced polyurethanes are playing a crucial role. Bombardier-Nordtrac OY in Finland uses Bayer MaterialScience’s Bayflex® 180 mineral fiber reinforced R-RIM polyurethane to make protective covers for ski sleds. This material provides exceptional impact resistance across a wide temperature range, making it suitable for harsh winter conditions. The cover, approximately 1.1 meters long, 1 meter wide, and 0.4 meters high, is both durable and lightweight, reducing maintenance costs and enhancing performance.
Beyond safety, Bayer MaterialScience also produces refractory composite polyurethane resin systems for heat treatment applications. Blendur®, a high-temperature resistant polyurethane resin system, is used in aerospace, railway, automotive, and electrical industries. Harald Rasselnberg, a polyurethane specialist, highlights that Blendur® can withstand temperatures up to 250°C and even higher for short periods. Its flame-retardant properties and thermal stability make it ideal for structural members, insulation, and casting applications.
Blendur® is compatible with various thermosetting plastic manufacturing techniques, including RTM and pultrusion, allowing for flexible use across different industries. The system comes in varying viscosities and can be customized with catalysts to control the working time. After being filled and reinforced, the material forms a dense crosslink structure, eventually curing into a dimensionally stable, thermally hardened plastic. Parts made with Blendur® exhibit minimal cold flow, ensuring consistent quality during production.