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For Immediate Release

BaySystems™ makes waves at COMPOSITES+POLYCON: Step-change in Long Fiber Injection process and special polyurethane formulation enables molding of strong, lightweight large parts

January 29, 2009

Pittsburgh, January 29, 2009 — A leading manufacturer of personal watercraft (PWC) posed a challenge to its supplier, Camoplast, Inc.: Find a way to manufacture a PWC hull that is lighter — but without sacrificing strength — and offers improved performance for the user. The catch? It also must be less expensive to produce.

The solution: a hull produced utilizing the next generation of long fiber injection (LFI) technology, including a proprietary formulation of Baydur® STR 814 polyurethane system. The Baydur® STR 814 polyurethane system is marketed through BaySystems™, the umbrella brand for the global polyurethane systems operations of Bayer MaterialScience. The 12-foot-by-3-foot PWC hull — the first-ever application of this technology — was on display at Bayer MaterialScience's booth at the recent COMPOSITES+POLYCON show.

Camoplast's can-do attitude
For decades, PWC hulls have traditionally been manufactured from glass fiber reinforced polyester resin using the robotic shell molding (RSM™) process or sheet molding compound (SMC) process. When searching for an alternative, Camoplast researched many technologies and materials, ultimately determining that LFI — if modified — could meet its customer's goal of producing a PWC hull that was strong and lightweight with a superior Class A finish, yet less expensive.

In LFI, long glass fibers are injected along with polyurethane resin in a one-step process: A fiberglass chopper is attached to the polyurethane dispensing mixhead, which is attached to a robot. The robot is programmed to move over the open mold cavity while simultaneously dispensing both the long glass fibers and the polyurethane resin in an open-pour method. At the end of the pour, the mold is closed to form the part.

There was one big catch: Due to the quick cure time of polyurethane resin, it was not possible to fabricate a part the size of the PWC hull.

Undeterred, Camoplast collaborated with material supplier Bayer MaterialScience and plastics processing equipment manufacturer KraussMaffei to devise what truly is a step-change and industry first: Camoplast Long Fiber (CLF™) technology.

To bring the process from concept to reality, Bayer MaterialScience developed a proprietary grade of its Baydur® STR 814 polyurethane system. This new grade features a 60-second open time (compared with a traditional open time of roughly 10 seconds), enabling the flow of the material and reinforcing glass into tight spaces, previously impossible, thereby making it possible to design-in strengthening ribs, etc. At the same time, KraussMaffei enhanced its proven LFI processing technology by nearly doubling the glass output capability from 180 grams/second to 300 grams/second, enabling the production of the highly reinforced structural parts.

The custom polyurethane formulation, along with specially designed KraussMaffei processing machinery and additional Camoplast innovations, makes it possible to produce large parts, such as the PWC hull.

Using polyurethane over the traditional glass reinforced polyester resins that were used in PWCs provides many benefits to the manufacturer as well as the consumer. Polyurethane is less dense than polyester, making it inherently lighter weight and thereby contributing to improved PWC acceleration. In fact, the hull produced with the CLF™ process weighs 25 percent less than the previous hull. Safety was also a consideration, according to Camoplast.

"The hull of a PWC is the largest and most vulnerable part of the vehicle. As it breaks over waves there is the chance that it could crack," said Yves Carbonneau, engineering director, Camoplast. "The part must have the best structural and mechanical characteristics while remaining lightweight for high performance. By using a light material, the Baydur® STR 814 system, reinforced with molded-in ribs, we achieved the necessary strength to withstand big waves and other safety issues that are inherent with a PWC."

Polyurethane resin is also a more environmentally friendly alternative to other types of resins like polyester, which contains VOC-emitting styrene that is a hazard to both the environment and machine operators. In addition, using polyurethane and CLF™ allows for faster, more automated production and a smaller manufacturing footprint, which are advantages in both cost-effectiveness and safety.

But that's not all. The use of CLF™ and polyurethane, along with tooling design guidance from KraussMaffei, enables Camoplast to use a nickel shell mold, which is less costly than the steel mold needed in the SMC process. Furthermore, by using in-mold coating technology, Camoplast is able to produce a painted, Class A surface right out of the mold, eliminating costly and time-consuming secondary painting operations.

"The innovative solution Camoplast developed, CLF™, is the most efficient way to achieve the company's high performance and aesthetic goals for the PWC hull," said Craig Snyder, market channel representative, Bayer MaterialScience LLC. "Because innovation is a key focus area for Bayer MaterialScience, naturally we're pleased to play a role in a project that is the first of its kind in the industry."

Effective March 1, 2007, Bayer MaterialScience has combined its entire global polyurethane systems business under the umbrella brand of BaySystems™. This change affects not only existing product brands in this segment — including Baydur® — but also the global network of polyurethane systems houses. More information about BaySystems™ can be found at www.bayer-baysystems.com.

Bayer MaterialScience LLC is one of the leading producers of polymers and high-performance plastics in North America and is part of the global Bayer MaterialScience business with nearly 15,400 employees at 30 sites around the world and 2007 sales of 10.4 billion euros. Business activities are focused on the manufacture of high-tech polymer materials and the development of innovative solutions for products used in many areas of daily life. The main segments served are the automotive, electrical and electronics, construction, medical, and sports and leisure industries. Our inorganic basic chemicals unit produces chlorine and related essential products for the chemicals industry.

Bayer Corporation, headquartered in Pittsburgh, is a subsidiary of Bayer AG, an international health care, nutrition and high-tech materials group based in Leverkusen, Germany. In North America, Bayer had 2007 net sales of 8.1 billion euros and employed 16,800 at year end. Bayer's three subgroups, Bayer HealthCare, Bayer CropScience and Bayer MaterialScience, improve people's lives through a broad range of essential products that help diagnose, prevent and treat diseases; protect crops and enhance yields; and advance automobile safety and durability.

For more information about BaySystems™, visit www.bayer-baysystems.com.

For more information about Bayer MaterialScience call 1-800-662-2927, e-mail naftainfo@bayerbms.com or visit www.bayermaterialscienceNAFTA.com.

For more information about Camoplast and CLF™ technology, visit www.camoplast.com or contact Yves Carbonneau at 450-548-1016.

For more information about plastics processing equipment manufacturer KraussMaffei, visit www.kraussmaffei.com or contact Lisa Shaner at 859-802-4067.

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This website may contain forward-looking statements based on current assumptions and forecasts made by Bayer Group or subgroup management. Various known and unknown risks, uncertainties and other factors could lead to material differences between the actual future results, financial situation, development or performance of the company and the estimates given here. These factors include those discussed in Bayer's public reports which are available on the Bayer website at www.bayer.com. The company assumes no liability whatsoever to update these forward-looking statements or to conform them to future events or developments.

Media Contact(s)
Name:	Thomas Erdner
Phone:	412-777-5200
Company:	Bayer MaterialScience
Email:	thomas.erdner@bayerbms.com

The first application of Camoplast Long Fiber technology, a major innovation that makes it possible to produce large parts using the long fiber injection (LFI) process, is the hull of a personal watercraft that will hit the market in summer 2009.