A Strong New Player on the Composite Scene

BlueWind Technology is a US manufacturer of molded composite parts for use in wind power, agriculture, petrochemical and other technically-demanding applications.

Since its launch in 2019, these parts were produced using resin infusion and plastic vacuum bags. This served the company well, supporting production of more than 2,000 molded nacelle covers for one of the world’s leading wind turbine suppliers.


Time for the Next Leap

By year five, however, BlueWind was looking for new ways to meet the evolving realities of the market. Like many manufacturers, they found themselves facing the twin challenge of growing production demands and a shrinking labor pool. What they needed was a simple production solution that would maximize output while at the same time minimize time, labor, and complexity. This prompted company leadership to reach out to the closed mold experts at Magnum Venus Products (MVP).

MVP’s closed mold department has 20 years’ experience in delivering production-efficient solutions to the international composites industry. Led by closed mold expert Charles Tur, MVP works closely with customers to develop a system and process that meets their particular needs. This includes training, implementation, and on-going support.

Exploring the Flex Mold Process

As a result of initial discussions with BlueWind, MVP made a visit to Pensacola, FL to assess the situation first-hand. After factoring in part sizes, glass layup, and desired daily volumes, MVP recommended a Flex Mold process for parts 100 sq. ft. or smaller.

This was followed by a week-long training and implementation session, where Tur guided BlueWind through construction of a reusable silicone vacuum bag, designed with critical production-friendly features, including:

  • Single injection port
  • Easy handling and vacuum sealing
  • Custom-configured resin channel to reduce injection time
  • No risk of trapped air
  • No part trimming after demolding
  • Reinforced with technical cloth for durability

The silicone of choice was Elkem’s BluesilTM RTV3724, a sprayable formula designed in partnership with MVP to deliver the gel-time and thixotropic properties ideal for flex mold construction. The formula is also styrene-resistant to protect structural integrity and extend the production life of the mold.

Silicone was applied in layers using the Patriot Duo Silicone System, which precisely mixes and meters parts A and B and allows for both spraying and “pouring” of the material so membrane thickness can be controlled throughout the process. Seals, ports, and resin channel are built in for a complete, reusable solution engineered for efficient part production.

Initial Results

With mold construction complete, the test team loaded fiberglass and was ready to inject their first part. To remove the potential for manual irregularities, the injection stage was automated with an MVP Innovator II System. A user-friendly interface allows a single operator to manage the task, even with minimal training, so BlueWind was able to take the helm from the start. A simple and efficient process can be repeated on every injection by leveraging Innovator controls, including:       

  • Precise mix-ratios of resin and catalyst
  • Precise volume metering with auto shut-off to prevent over-injection
  • Pressure control maintains ideal flow rate throughout
  • Catalyst alarm option eliminates risk of over- or under-catalyzed parts  
Continuing Results

The Flex mold process and result was a clear success. The next test was durability over time: would the silicone mold perform the same for part 100 as it did for part 1? BlueWind has now pulled more than 60 parts from the original silicone skin with no visible or functional degradation. Every part they inject reduces waste by 16.5 lbs (7.5 kg). The savings in time, labor, and material keep piling up over time.

“The process stability, surface finish and environmental impact are remarkable. We’ve already produced over 60 parts using the same silicone skin, and operators are eager to see the upgrade on more molds.”

–Carlos Sinhori, BlueWind Industrial Director

[from JEC article of 05.08.25]

Planning for On-Going Improvement and Sustainability

With the first silicone mold in place and creating measureable value, BlueWind is now in the process of building 8 additional molds on their own. MVP continues to provide guidance and technical support along the way to ensure our customer gets the most from their investment. Not only will the new flex molds multiply productivity, the transition will enable BlueWind to eliminate 35 tons of waste per year! It’s this kind of forward thinking that helped the company win a prestigious 2025 Sterling Award for Manufacturing Business Excellence (SMBE).

MVP is honored to partner with BlueWind as they continue to grow with excellence. If you would like to learn more about flex molding, closed mold support, or MVP precision-injection systems, contact us at mvpind.com/contact-us.

Or you might consider attending one of our Closed Mold Training sessions featuring Charles Tur. These are conducted three times a year at the MVP manufacturing center in Knoxville, TN. You can visit our registration page to learn more.