Reaction injection molding

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Reaction injection molding (RIM) is similar to injection molding except thermosetting

polymers are used, which requires a curing reaction to occur within the mold.

Common items made via RIM include automotive bumpers, air spoilers, and fenders.[1]

Contents
[hide]

 1 Process
 2 Advantages and disadvantages
 3 Tooling
 4 References

[edit] Process
First, the two parts of the polymer are mixed together. The mixture is then injected into the mold
under high pressure using an impinging mixer. The mixture is allowed to sit in the mold long
enough for it to expand and cure.[1]

If reinforcing agents are added to the mixture then the process is known as reinforced reaction
injection molding (RRIM). Common reinforcing agents include glass fibers and mica. This
process is usually used to produce rigid foam automotive panels.[1]

A subset of RRIM is structural reaction injection molding (SRIM), which uses fiber meshes
for the reinforcing agent. The fiber mesh is first arranged in the mold and then the polymer
mixture is injection molded over it.[1]

The most common RIM processable material is polyurethane, but others include polyureas,
polyisocyanurates, polyesters, polyepoxides, and nylon 6. For polyurethane one component of
the mixture is polyisocyanate and the other component is a blend of polyol, surfactant, catalyst,
and blowing agent.[1]

[edit] Advantages and disadvantages

Reaction injection molding can produce strong, flexible, lightweight parts which can easily be
painted.[citation needed] It also has the advantage of quick cycle times compared to typical vacuum cast
materials.[citation needed] The bi-component mixture injected into the mold has a much lower viscosity
than molten thermoplastic polymers, therefore large, light-weight, and thin-walled items can be
successfully RIM processed. This thinner mixture also requires less clamping forces, which leads
to smaller equipment and ultimately lower capital expenditures. Another advantages of RIM
processed foam is that a high-density skin is formed with a low-density core.[1]

The disadvantages are slow cycle times, compared to injection molding, and expensive raw
materials.[citation needed]

[edit] Tooling
Machined steel or aluminum; cast aluminum; silicone rubber;epoxy resin. The machines can be
large or small depending on the size of part required.

[edit] References
1. ^ a b c d e f Ashida, Kaneyoshi (2006), Polyurethane and related foams: chemistry and
technology

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o CNC Machining
o Finishing & Assembly
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o Rapid Injection Molding
o Design for Manufacturability (DFM)

Left: Medical diagnostic device skins made with 9 RIM pieces.

 

Medical enclosure molded (RIM) from cast kirksite tooling.

Electronics enclosure made from RIM process.

Reaction Injection Molding (RIM)

Reaction Injection Molding (RIM) produces parts with intricate detail that are dimensionally
stable, chemically resistant, physically tough, and wear resistant. This process is an excellent
choice for larger plastic parts produced in short run or low volume production quantities.

 Polyurethane molded parts in 2-5 weeks

 Excellent flowability allows molding complex geometry including: louvers, ribs, bosses
and openings
 Superior cosmetic appearance for visibly critical applications
  Superb encapsulation ability

The process takes its name from a chemical reaction that occurs within the tool. The plastics
used are thermosets, either polyurethanes or foamed polyurethanes. The two components that
produce the polyurethane are mixed just prior to injection into the tool. With the low viscosity
and low injection pressures, large, complex parts can be produced economically in low
quantities.

Considerable design freedom is possible, including thick and thin wall sections that are not good
for injection molding, due to the uniform shrink characteristics. Foamed polyurethanes are
natural thermal and acoustic insulators. Excellent flowability allows for the encapsulation of a
variety of inserts.

Reaction injection molding is used in many industries for many types of parts. While bumpers
for vehicles are produced in this process, most applications are for large, complex parts produced
in quantities less than 5,000 units. Examples include panels for electrical equipment, enclosures
for medical devices, and housings for computer and telecommunications equipment.

If you think that your next project may benefit from Reaction Injection Molding, contact us to
learn the advantages and differences when compared to other plastic molding processes.

For detailed specifications, view a technical data sheet for Reaction Injection Molding.

 HTML
 PDF (download)

Watch Video
The Reaction Injection Molding (RIM) process blends the materials of rubber molding
(thermosets) with the tools and techniques of injection molding.

Click on the video to the right to see how this comes together.

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Technical Information: Reaction Injection
Molding (RIM)
Download the PDF version of this document

What is it?
Simply stated, in this process two liquid components - - component "A", a formulated polymeric
isocyanate, and component "B", a formulated polyol blend, are mixed in a high pressure head
and then pumped into a mold cavity. A reaction then occurs in the mold, resulting in a high
density polyurethane structural foam part.

How, Why & When to Use It:

1. To produce covers, bases, keyboards, bezels and housings for computers, business
machines and medical applications.
2. For prototype through medium volume applications (1 - 2,000 pieces).
3. There is considerable design freedom to produce complex shapes.
4. Molds can be resin, spray metal, cast aluminum or machined aluminum.
5. Tooling is low cost and allows for ease of modification.
6. A variety of castings, sheet metal and threaded inserts can be molded in place.
7. Alternative foams are available which offer a range of insulating properties.
8. UL traceability.

Design & Technical Information

Size

Up to 48 in.

Weight

Up to 18 lbs.

Finish

If required:

 No bake prime and paint

 RF shielding
 Silk screening
Wall thickness

Can vary but should not be less than 1/4 in., although local thicknesses of 1/8 in. can be
produced.

General tolerance

Note: tighter tolerances can be negotiated.

  0 in. -   3 in. +/- 0.010 in.

  3 in. -   6 in. +/- 0.015 in.
  6 in. - 12 in. +/- 0.020 in.
12 in. - 18 in. +/- 0.030 in.
18 in. - 48 in. +/- 0.040 in.

Holes

All holes molded to size.

Draft

Recommended 1 - 2 degrees, but no draft is possible when specified.

Radii and fillets - should be as liberal as possible (1/8 in. to 1/4 in.).

Density

Can be varied, depending on foam used, to offer a variety of insulation properties.

A variety of materials are available that offer a range of insulating and mechanical properties
with 94V-0.
Detailed specification sheets are available on request (email requests to
sales@armstrongmold.com)

Comparison Chart RIM vs. Injection Mold Properties

Modified
Material Units RIM Polystyrene ABS
PPO
Specific gravity   0.85 0.85 0.89 0.85
Thickness (in.) 0.25 0.25 0.25 0.25
Flexural modulus (psi) 220,000 275,000 240,000 261,000
Flexural strength (psi 9,500 5,700 6,000 6,800
Tensile strength (psi) 5,800 2,300 3,000 3,400
Elongation (%) 10 20 -- 16
Gardner impact + + (in-lb) 74 28 52 55
 Modified
Material Units RIM Polystyrene ABS
PPO
Falling ball (ft-lb) - - -- -- 18
Dart impact (ft-lb) - - -- 10 --
Heat distortion temperature          
  @ 66 psi (F) 212 183 177 205
  @ 264 psi (F) 180 168 162 180
The above properties are intended as a guide only and may vary depending on thickness and
shape.