When seeking innovative materials for industrial applications, one product stands out for its versatility, efficiency, and quality—Dualite® Expanded Microspheres. Made in the USA, these polymeric microspheres secure a reliable domestic supply chain, ensuring availability and consistency for organizations in the automotive, composites, sealants, and coatings industries. 

This article explores why Dualite® Expanded Microspheres are an essential component for manufacturers aiming to enhance product performance while reducing costs. 

What Are Expanded Microspheres? 

Expanded microspheres are lightweight, hollow thermoplastic spheres used as functional additives. These spheres are made up of a polymer shell encapsulating a gas. During the manufacturing process, these microspheres expand upon exposure to specific temperatures, creating ultra-low-density particles that enhance formulations. 

Dualite®, a product of Chase Corporation, supplies expanded microspheres in a range of particle sizes (from 25 to 150 microns) and densities, making them adaptable to a wide variety of industrial applications. Our coated and expanded products offer additional benefits, such as non-explosive properties, better compatibility with formulations, and reduced tendency to float out. 

Benefits of Dualite® Expanded Microspheres 

These versatile microspheres contribute immense value to products across industries. Below are some of the key advantages that set them apart. 

1. Cost Reduction 

Dualite® Expanded Microspheres reduce raw material costs by acting as fillers or extenders. By occupying significant volume without adding weight, they minimize the amount of high-cost raw materials like polymers, resins, and adhesives required in formulations. 

2. Weight Reduction 

Weight reduction is crucial in industries like automotive and aerospace, where decreased load translates to better fuel efficiency and optimized performance. Incorporating these ultra-light microspheres in underbody coatings, lightweight polymer formulations, and sealants makes achieving this goal feasible without compromising structural integrity. 

3. Improved Machinability and Workability 

The compressible nature of Dualite® microspheres enhances the machinability of materials, improving workability in manufacturing processes. This results in easier handling and reduced energy consumption during mixing and application. 

4. Enhanced Performance 

Dualite® microspheres elevate product performance, offering benefits such as improved sound dampening, thermal insulation, and resistance to cracking or shrinkage. These qualities are vital for applications like automotive underbody coatings, sealants, and construction materials. 

5. Lower VOC Content 

Environmental regulations increasingly require manufacturers to reduce volatile organic compound (VOC) content in products. Dualite® Expanded Microspheres help lower VOC emissions in paints and coatings, aligning your product with eco-friendly standards while maintaining outstanding quality. 

6. Volume Expansion for Maximum Coverage 

With their unique ability to expand during heat exposure, unexpanded microspheres can be used to achieve greater material coverage and enhance thermal insulation properties. 

Key Applications Across Industries 

Dualite® Expanded Microspheres support diverse industrial uses. Below are examples of how they are integrated to enhance specific applications. 

• Automotive Industry 

Widely used in underbody coatings, lightweight composites, and sound deadening materials, these microspheres help reduce vehicle weight while improving durability and acoustic properties. 

• Sealants and Adhesives 

By improving filler distribution and consistency, Dualite® microspheres reduce shrinkage and enhance rheological properties in various sealant applications. 

• Coatings Industry 

From aircraft coatings to roof materials, expanded microspheres optimize thickness and durability, providing lightweight solutions without compromising structural or aesthetic properties. 

• Composites Manufacturing 

These microspheres combine seamlessly with FRP compounds and polymers to create lightweight yet durable composite materials for construction, energy, and medical equipment. 

Made in the USA for Hassle-Free Supply Chains 

Choosing a U.S.-manufactured product like Dualite® offers significant supply chain advantages. The domestic manufacturing ensures consistent quality and reduces logistical risks related to international shipping or unforeseen supply chain disruptions. This reliability is particularly valuable for industries with time-sensitive production cycles, like aerospace and automotive. 

Why Dualite® Expanded Microspheres Are a Superior Choice 

With proven effectiveness, versatility, and a U.S.-based supply chain, Dualite® Expanded Microspheres offer unmatched dependability for businesses looking to innovate in materials design and production. Their ability to reduce costs and environmental impact while enhancing product quality makes them an indispensable additive for forward-thinking manufacturers. 

Want to learn more about the impact Dualite® Expanded Microspheres can have on your products? Contact us today and explore tailored solutions for your industry needs.