Our Services
Normally the customers’ polymer need is a subset of a larger product development effort. Our objective is to become a project team leader with responsibility for development of the polymer component.
We strive to own our customers’ polymer problems.
Bay Materials’ facility provides state of the art capability, and we relieve the customers need to build polymer expertise and a facility that may become idle at project completion.
We offer cost efficient turnkey solutions.
Our first approach to solving a polymer problem is to determine if an off-the-shelf solution exists. Our customers usually find Bay Materials when nothing off-the-shelf fits the application. If an existing materials does not meet the customer’s need we will consider modifying an existing polymer system to satisfy the need. It this is not feasible, we will work with the customer to define the “perfect material” that drives a “target specification” for a new material and develop the new material.
Over our history, we have developed new polymer systems for a broad array of needs.
Examples:
- A spray Forming Solution for a medical device
- A ridged polyurethane for an orthodontic application
- An adhesive system that bonds to COC, (a material nothing sticks to)
- An extremely sharp melting point compound for cooking timer
See More Case Studies
1.Problem Clarification
A common theme in initiating a project:
- The customer “knows what he/she wants”
- The project manager “has uncertainty in what can be delivered”
- The technical expert “knows what cannot be delivered”
Bay Materials believes that aligning expectations and clarifying the mission is the most critical phase in launching a successful development. Given that we as materials experts bring new options towards solutions alternatives, often the scope, cost, and technical direction are impacted.
We complete an extensive effort initially such that “Problem Clarification” is included as a component of a contract proposal, and we do our very best to set realistic expectations in terms of project scope, timing, and cost.
2.Concept Building
Our initial approach with a customer is to understand “their problem” and complete a preliminary analysis to cultivate alternatives. Solutions proposed can range from the “use of an off the shelf polymer” to the “development of a custom polymer”. Obviously the scope and cost of these extreme examples vary dramatically.
The Concept Building Phase is usually a few weeks to a few months in duration, and is designed to clarify a project in fine detail so our customer knows what they are committing to and have a good sense of risk.
3.Project Implementation
Due to the nature of Product Development, every problem we face is unique. Through our extensive experience in developing leading edge solutions, we have learned to minimize uncertainty and risk in the process.
Development of a polymer solution is an iterative process encompassing:
- Develop “Material Specification”
- Source candidate materials
- Establish experimental screening methods
- Screen candidate materials
- Optimize for application
- Process trials and scale up
- Develop commercial vendor
- Complete risk assessment, FMEA and Documentation
A key consideration in developing a polymer application includes, “life after product launch”, which is dependent on the polymer, and the longevity of base material availability. Our experience has taught us to focus on materials that are offered by multiple chemical companies, that are projected to be available for decades, and that are formulated with chemical components that are inherently safe.
4.Intellectual Property
Bay Materials has a strong background in creating and managing intellectual property. It is a normal component of our mind set to be cognizant of inventions and/or trade secrets.
If we are extending the art of a polymer formulation or related application, IP must be considered in the process. Both the avoidance of patent infringement and the establishment of new IP is an outcome of our work.
Bay Materials offers a range of supports related to IP from a first order literature search, to disclosing inventions and completing experiments to reinforce drafting of a patent application.
Bay Materials has the experience, knowledge, and expertise to support process development and scale up. We know how to avoid pitfalls!
Life begins with a polymer system when it cools off from the final forming process; Molecular orientation, degree of crystallinity, chemical stability, among other properties all impact the final properties of the article. Everything matters down to the fine details!
We have learned through experience that a manufacturing process must be robust from a processing window perspective, and be process-able on appropriate scale equipment. Bay Materials has a broad experience with all processes utilized for polymer production of polymer based products. We maintain a “small scale” process lab in-house, and we have relationships with large manufacturers for scale up and vendor development.
From our perspective, “the project is complete when the customer can place an order on a vendor”, and have confidence in the outcome.
Bay Materials has built a facility capability to formulate, analyze, develop, and scale-up polymer systems.
Chemistry Laboratory
Complete wet lab with capability to build polymers from monomer components, modify polymers, and conduct general chemical activities.
Analytical Laboratory
A state of the art set of instruments necessary to fully analyze and characterize polymer materials and other components found in polymer systems; thermal analysis, spectrometry, rheometry, surface properties, and structural properties. (Find out more…)
Polymer Process Laboratory
Polymer properties are impacted by the process by which they were formed. Thermal history, process variables, and process equipment can all impact the final article. Efficient screening techniques are used initially in the polymer selection or development phase, but the final development phase requires the utilization of customary process equipment.
Our process laboratory is designed to quickly produce functional articles, or test samples, with small volumes of start materials. At this phase of development, the articles produced are normally adequate for product qualification. (Find out more…)
