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Manufacturers are constantly seeking innovative ways to reduce product weight—particularly for high-volume goods. Reducing weight not only contributes to significant cost savings and improved environmental performance, but it also enhances design flexibility, allowing for the inclusion of additional features or materials without exceeding weight constraints. One advanced solution is the use of polymer microspheres.

These lightweight fillers can be incorporated into product formulations to dramatically lower overall weight and reduce raw material costs—all without compromising performance or reliability. Additionally, they help decrease volatile organic compound (VOC) emissions and improve machining and processing characteristics, depending on the application.

What are Dualite Polymer Microspheres?

Dualite^® microspheres from Chase Corporation are specialized polymer microspheres manufactured using a patented process that controls both expansion and coating application. Made from a flexible polymer shell, these ultra-lightweight fillers are available in a range of particle sizes, densities, and material compositions.

They can be blended into plastics, resins, adhesives, and composites, offering multiple benefits: weight reduction, cost savings, density control, and environmental advantages. These attributes make Dualite an ideal solution across a broad range of industries and end-use applications.

Dualite polymer microspheres are available in two forms:

1. Unexpanded Microspheres – Solid spheres that expand during processing and serve as alternatives to traditional chemical blowing agents.
2. Pre-Expanded Microspheres – Already expanded and coated with fine mineral particles like calcium carbonate, these can be directly incorporated into products.

How Can these Microspheres Help Reduce Product/Component Weight?

Incorporating Dualite microspheres into your product formula can result in substantial weight reductions. Due to their extremely low density, Dualite microspheres can volumetrically replace denser, more expensive materials. Even small additions—just 2–3% by weight—can reduce overall product weight by up to 40–50%.

This reduction makes products easier to handle (both in-house and for customers), decreases freight and material costs, and minimizes product sag or “slump” on vertical surfaces.

Applications include:

• Paints
• Coatings
• Adhesives
• Sealants

This is especially advantageous for manufacturers who sell by volume. For a visualization of weight reduction potential, refer to the chart on page 8 of the Dualite brochure, which illustrates specific gravity reductions using Dualite E™ 065-135D at various load levels.

To determine the potential in your own products, Chase Corporation offers a spreadsheet tool where you can input your formulation, raw material costs, and densities.

Environmental Benefits of Using Dualite Microspheres

In addition to performance and cost advantages, Dualite® polymer microspheres deliver several meaningful environmental benefits:

• Lower VOCs – Minimized solvent migration improves indoor air quality and reduces health hazards during production and application.
• Higher R-Value – Enhanced thermal resistance in finished products.
• Faster Drying – In water-based systems, less energy is required as microspheres occupy more volume.
• Improved Workplace Safety – Replacing chemical blowing agents reduces risks to workers and the environment.
• Better Fuel Efficiency – Lighter coatings and sealants contribute to improved vehicle efficiency.
• Noise Reduction – Sound dampening properties reduce vibrations and emissions.
• Material Efficiency – Enables reduction of base material without sacrificing strength or flexibility.

Improved Surface Quality

Dualite microspheres can also improve surface appearance. Their lightweight properties allow them to migrate to the product’s surface, resulting in a smoother finish. Additionally, they help absorb impact energy, making components more resistant to cracking or breakage.

Calculate Savings With Polymer Microspheres

Dualite microspheres provide a cost-effective alternative to expensive resins while preserving key product properties. The benefits extend beyond material substitution—they also reduce shipping costs and lower energy use.

Example Volume Cost Calculation:
For a 12 lb/gallon formula costing $0.92/lb, the volume cost =
12 x $0.92 = $11/gallon

Chase Corporation provides a downloadable cost-saving calculator to help manufacturers assess potential savings when substituting raw materials with microspheres in adhesives, composites, or resins.

To evaluate your application costs, download the Cost Savings Calculator Tool.

Industries and Applications

With various grades available, Dualite microspheres are tailored to diverse applications:

• Automotive & Transportation – Used in tires, underbodies, panels, and sound-dampening layers. Weight savings improve fuel economy and reduce costs.
• Construction Products – Incorporated into roof coatings, patching compounds, insulation foams, and cement adhesives. Lower density materials are easier to handle and reduce equipment requirements.
• Textiles – Serve as fillers in paints and coatings, reducing the need for expensive pigments.
• Packaging – Improve weight, processability, durability, and cost-efficiency of packaging adhesives and sealants.
• Aerospace – Enable lighter composites for increased fuel efficiency and structural performance.
• Marine – Suitable for coatings and composites used in hulls, interiors, and marine structures, offering durability and reduced environmental wear.

Ready to replace your raw materials with Dualite? 

Chase Corporation offers multiple grades of Dualite polymer microspheres, each with specific densities, particle sizes, and coating types to meet your application’s performance needs. Explore your options and optimize your formulations for cost, weight, and environmental performance.

H.M. Royal is a trusted supplier of Dualite microspheres and other performance additives including aramid fibers and odorants.  Our team of experts can help you determine the best choice for your needs. Email us at in**@*****al.com or refer to www.hmroyal.com to find out more about the products we represent.