Worldwide the current consumption of thermoset resins across the whole industrial spectrum amounts to 21.6 million tonnes. Industry growth rates are forecast to be in excess of 2.5 per annum. The worldwide industry is thriving and producing lightweight, high performance, high quality products for an ever-expanding range of markets.

Thermosets include a wide range of materials: acrylics, alkyds, amino resins, bismaleimides, epoxy, furane, phenolics, polyimides, unsaturated polyesters, polyurethanes and vinyl esters. New materials are being developed such as cyanate esters, silicones and arylzene resins, together with hybrid resins. This report focuses on the most widely used materials with shorter sections on speciality resins.

The applications of thermosets are many and varied. One of the primary uses is as the matrix in composite materials. Composites are now accepted as high performance engineering materials in many fields such as automotive, aerospace and marine. They are made using a range of techniques, which are outlined in this report, from autoclave moulding to resin transfer moulding. Key developments and trends are indicated here.

Adhesives are another major application area for thermosets and progress has been rapid. For example, a few years ago adhesives were restricted to relatively low performance applications, while today the range of formulations makes it possible to assemble aircraft and automotive components. Construction is a major market. Resin consumption is difficult to estimate. However, available data can be extrapolated to obtain a feel for the market size.

A large volume of thermosets is used in the coatings industry. This has undergone rapid change in recent years as manufacturers strive to reduce VOC emissions, by reducing the use of solvents and bringing in ultraviolet curing formulations.

Recycling is another environmental issue that is being tackled by manufacturers. Thermoset materials are designed for a long lifetime and can therefore be difficult to break down. However, methods of re-use and recycling are available. Innovations in materials include the use of natural fibre reinforcement in composites and the application of biopolymers as the matrix materials.

It is difficult to estimate the size of the thermoset industry in global regions and worldwide as many companies produce their own resin in-house and major suppliers are generally reluctant to issue figures. However, the authors of this report have decades of experience. Trevor Starr has worked on market data for the thermoset industry for several years, compiling statistics for books. His expertise and knowledge have proven invaluable in assessing the current markets and potential future growth and developments in this Thermoset Resin Market Report.

Key features

1 About This Report
1.1 Introduction
1.2 Scope of the Report
1.3 Geographical Focus
1.4 Methodology
1.5 Units and Terms Used in the Report
1.6 Authorship

2 Executive Summary
2.1 Market Share
2.2 Production Capacity and Operating Rates
2.3 Developments
2.4 Material Substitution
2.5 Environmental Issues
2.6 Recycling

3 Thermoset Resin Types - Production Outline
3.1 Acrylics
3.2 Alkyds
3.3 Amino Resins
3.4 Bismaleimides
3.5 Epoxy
3.6 Furane
3.7 Hybrids
3.8 Phenolics
3.9 Polyimides
3.10 Unsaturated Polyester
3.11 Polyurethanes
3.12 Vinyl Esters
3.13 Other Thermosetting Resins
3.13.1 Cyanate Esters
3.13.2 Silicone-Based
3.13.3 Resins Under Development
References

4 Applications
4.1 Introduction
4.2 Adhesives
4.2.1 Epoxy
4.2.2 Unsaturated Polyesters
4.2.3 Phenolic
4.2.4 Others
4.3 Buttons
4.4 Casting and Solid Surface Applications
4.5 Coatings
4.5.1 Arylzene Resins
4.5.2 Blocked Isocyanates
4.5.3 Epoxies
4.5.4 Melamine Resins
4.5.5 Phenolic
4.5.6 Polyesters
4.5.7 Polyurethanes
4.5.8 Powder Coating
4.5.9 Vinyl Esters
4.5.10 Others
4.5.11 Ultraviolet Cure
4.6 Composite Matrices
4.6.1 Processing and Fabrication
4.6.1.1 Autoclave Moulding
4.6.1.2 Contact-Moulding (Hand Lay) and Spray Deposition
4.6.1.3 Cold-Press and Vacuum Bag Moulding
4.6.1.3 Filament Winding
4.6.1.4 Continuous Lamination
4.6.1.5 Hot-Press Moulding
4.6.1.6 Pultrusion
4.6.1.7 Resin Injection (Transfer) or Resin Infusion Moulding
4.6.2 Fire Retardant Composite Applications
4.6.3 Matrices for Composites
4.6.3.1 Acrylics
4.6.3.2 Bismaleimides
4.6.3.3 Epoxy
4.6.3.4 Furanes
4.6.3.5 Hybrids
4.6.3.6 Melamine and Urea Formaldehyde Resins (Aminos)
4.6.3.7 Phenolic
4.6.3.8 Polyimides
4.6.3.9 Modified Polyimides
4.6.3.10 Unsaturated Polyesters
4.6.3.11 Urethanes
4.6.3.12 Vinyl Esters
4.6.4 Composite Applications
4.6.4.1 Aerospace
4.6.4.2 Chemical and Corrosion
4.6.4.3 Energy Generation
4.6.4.4 Infrastructure
4.6.4.5 Marine
4.6.4.6 Transport
4.7 Encapsulation
4.7.1 Epoxies
4.7.2 Hybrids
4.7.3 Others
4.8 Flooring
4.8.1 Epoxies
4.8.2 Polyesters and Vinyl Esters
4.8.3 Phenolic and Furane
4.9 Gelcoats and Pigment Pastes
4.10 Paints and Lacquers
4.11 Pastes and Putties
4.12 Polymer Concrete
4.13 Printing Inks and Associated Applications
4.14 Tooling
4.15 Friction Materials
4.16 Foundry and Refractory Products
4.17 Wood Products
4.18 Foams
4.19 Mineral Wool Insulation
4.20 Moulding Compounds
4.21 Abrasives
4.22 Rubber Compounding Resins
4.23 High Pressure Laminates
4.24 Sports Goods
4.25 Others
References

5 Market Development
5.1 Introduction
5.2 Market Issues
5.3 Epoxy Based Resins
5.4 Epoxy Vinyl Ester Based Resins
5.5 Phenolic Resins
5.6 Polyimide Based Resins
5.7 Polyurethane Based Resins
5.8 Unsaturated Polyester Resin Systems
5.9 Conclusions

6 Consumption - Current and Future
6.1 Composites Matrices
6.1.1 North America
6.1.1.1 Market Size
6.1.1.2 Comment
6.1.2 Western Europe
6.1.2.1 Market Size
6.1.2.2 Comment
6.1.3 Eastern Europe
6.1.3.1 Market Size
6.1.3.2 Comment
6.1.4 Asia-Pacific
6.1.4.1 Market Size
6.1.4.2 Comment
6.1.5 Latin America
6.1.5.1 Market Size
6.1.5.2 Comment
6.1.6 Rest of the World
6.1.7 Summary and Analysis
6.2 Unreinforced Unsaturated Polyester Resin: Applications
6.2.1 North America
6.2.2 Western Europe
6.2.3 Eastern Europe
6.2.4 Asia-Pacific
6.2.5 Latin America
6.2.6 Rest of World
6.2.7 Summary
6