NCC’s signature Rapid Fiber Preform process was used to develop a motorbox cover for SeaRay Marine Division of Brunswick Corporation. A steel screen tooling for this program was designed to fit P4 and economically built by Thorton Industries. NCC constructed the motorbox preform of a layer of veil for cosmetic appearance and chopped glass consolidated with a powdered thermoset binder. The preform was sprayed onto the female screen so that a well-controlled chopped veil layer could be applied first to create the show surface. Traditionally, all parts had been sprayed onto the male screen. NCC had to modify programming to overcome a dramatic change in the pressure drop throughout this routine and maneuver the robot head down inside to spray the walls. NCC’s experienced technical specialists and advanced programming produced a full net shape, net size part in a time frame of one month. The preforms were successfully impregnated by a resin transfusion process (RTM) in a polymer mold at the SeaRay facility in Tellico, Tennessee. The motorbox preform developed by NCC dramatically reduced cycle and produced a high quality preform with a cosmetic surface. This new technique was verified as an improved process over the laborious hand lay-up of mats previously used to produce the covers. 
Composite Motor Covers