A garden & lawn customer had a heat problem. Plastic parts were melting due to the intense heat generated by the engine. We were asked to provide a product that would reduce the direct heat to stop melting the plastic components in a given area. After several proposed materials based on different price points and several thermal tests, the decision was made to use a steel shield with a heat absorbing material attached to it. The material is an aluminum faced polyester/fiberglass blend. We sourced the steel shield and then attached the material with a PSA (pressure sensitive adhesive), providing a complete, ready to use, finished product.

We were approached to make a baffle that would reduce the overall noise produced by a generator. The concept was to get as much sound energy absorbed before it could vacate the generator through the exit vents. After a few prototype runs, the acoustic data was gathered and we settled on a 6” thick polyurethane faced acoustic ether foam with 20 degree baffles spaced 3” apart. We added a PSA (pressure sensitive adhesive) on the back to aid in easy installation. We stayed on budget and delivered a baffle that reduced the generator’s noise significantly.

A large vehicle company approached Milcut to design from scratch a defroster filter for a new line of trucks. We have years of experience with air filtration products but this one had specific parameters. The Chief Engineer presented us with the following list of items to consider. First and foremost, the defrost filter had to filter the appropriate size particulate. With the broad range of reticulated filter foam we use, this was the easy part. We discussed the air flow (PPM-Parts Per Million) that would be going through the filter area and zeroed in on a few PPI (pores per inch) that we believed would work best. After testing, we settled on a 30PPI reticulated filter foam. Secondly, the filter needed to be serviced easily if it were to get clogged or needed replacement. Next, it was going to be directly exposed to the passenger of the vehicle. This meant it needed to withstand the possibility of someone poking the filter so durability was a must. The final criteria, as is in most cases, was it needed to be available for the first run of trucks, ASAP.

We immediately looked at what materials could be combined with the filter foam to add the needed rigidity. Leaning on our expertise in plastics, we quickly determined that a thin ABS plastic could serve as the framework to hold our filter foam in place. Once we had solid dimensions of the space it was to fit in, we made a prototype from the ABS that framed the 30 PPI reticulated filter foam. Now we had to determine how to hold the foam within the framework of the ABS. We took some knowledge from the air filter industry and employed a fiberglass screen that is often used in pre-filter manufacturing designed specifically to add rigidity to air filters. All components were then RF sealed to provide the functional defroster filter that is currently being employed today.