IDI Composites International, a premier global formulator and manufacturer of thermoset molding compounds, has announced that Utility Associates (www.utility.com) of Covington, Georgia, a major manufacturer of mobile operations information communication systems, has converted its OnComm Rocket™ advanced onboard mobile communications hub from a metal-based design to IDI’s BMC 44-10 thermoset bulk molding compound. 

According to Utility Associates General Manager Ted Davis, “the OnComm Rocket™ was proving to be so popular with customers (sales had increased 100% from the prior year) that we were having difficulty keeping up with production requirements during demand ‘surges’ because of the product’s metal-based design.” The unit’s electronic components and firmware were housed in a tamper-proof lockbox that included 30 different parts, some of which were laser-cut, formed, welded, plated, and then assembled to make one part. Several suppliers were involved. Lead times were excessive.

According to Davis, the solution needed to be one that not only reduced product complexity, but also one that would be considered a quality and aesthetic upgrade, was equally as strong as steel, and was more reproducible. One of Utility’s suppliers, Versatile Mold & Design, Inc. (www.versatilemd.com) of Rutledge, Georgia, suggested IDI’s bulk molding compound as a solution. Utility was aware of some of the benefits of fiberglass reinforced polyester molding compounds –such as high specific gravity– because of their use in applications such as electrical circuit breakers.

With the help of Versatile Mold and IDI, the Rocket™ was redesigned. The part count was reduced from thirty to five. Several manufacturing processes were eliminated. The supply chain was reduced from several suppliers to just two. Cost, although it was not a reason for investigating alternative materials, was also reduced. Most importantly, however, through the use of the composite material, Utility was able to more effectively handle demand surges by maintaining a much higher inventory of “kitted” parts.