Reaction injection molding (RIM) is similar to

injection molding Injection moulding (U.S. spelling: injection molding) is a manufacturing process for producing parts by injecting molten material into a mould, or mold. Injection moulding can be performed with a host of materials mainly including metals (for ...

except thermosetting

polymer A polymer () is a chemical substance, substance or material that consists of very large molecules, or macromolecules, that are constituted by many repeat unit, repeating subunits derived from one or more species of monomers. Due to their br ...

s are used, which requires a curing reaction to occur within the

mold A mold () or mould () is one of the structures that certain fungus, fungi can form. The dust-like, colored appearance of molds is due to the formation of Spore#Fungi, spores containing Secondary metabolite#Fungal secondary metabolites, fungal ...

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

Process

The two parts of the polymer are mixed together, usually by injecting them under high pressure into an impinging mixer. Then the mixture is injected under lower pressure into a mold. The mixture is allowed to sit in the mold long enough for it to expand and

cure A cure is a substance or procedure that resolves a medical condition. This may include a medication, a surgery, surgical operation, a lifestyle change, or even a philosophical shift that alleviates a person's suffering or achieves a state of heali ...

. If reinforcing agents are added to the mixture then the process is known as reinforced reaction injection molding (RRIM). Common reinforcing agents include

glass Glass is an amorphous (non-crystalline solid, non-crystalline) solid. Because it is often transparency and translucency, transparent and chemically inert, glass has found widespread practical, technological, and decorative use in window pane ...

fiber Fiber (spelled fibre in British English; from ) is a natural or artificial substance that is significantly longer than it is wide. Fibers are often used in the manufacture of other materials. The strongest engineering materials often inco ...

s and

mica Micas ( ) are a group of silicate minerals whose outstanding physical characteristic is that individual mica crystals can easily be split into fragile elastic plates. This characteristic is described as ''perfect basal cleavage''. Mica is co ...

. This process is usually used to produce rigid foam automotive panels. A subset of RIM 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. The most common RIM processable material is

polyurethane Polyurethane (; often abbreviated PUR and PU) is a class of polymers composed of organic chemistry, organic units joined by carbamate (urethane) links. In contrast to other common polymers such as polyethylene and polystyrene, polyurethane term ...

(known generally as PU-RIM),. but others include polyureas, polyisocyanurates,

polyester Polyester is a category of polymers that contain one or two ester linkages in every repeat unit of their main chain. As a specific material, it most commonly refers to a type called polyethylene terephthalate (PET). Polyesters include some natura ...

polyphenol Polyphenols () are a large family of naturally occurring phenols. They are abundant in plants and structurally diverse. Polyphenols include phenolic acids, flavonoids, tannic acid, and ellagitannin, some of which have been used historically as ...

s, polyepoxides, and nylon 6. For polyurethane one component of the mixture is

polyisocyanate In organic chemistry, isocyanate is the functional group with the formula . Organic compounds that contain an isocyanate group are referred to as isocyanates. An organic compound with two isocyanate groups is known as a diisocyanate. Diisocyan ...

and the other component is a blend of

polyol In organic chemistry, a polyol is an organic compound containing multiple hydroxyl groups (). The term "polyol" can have slightly different meanings depending on whether it is used in food science or polymer chemistry. Polyols containing two, th ...

surfactant Surfactants are chemical compounds that decrease the surface tension or interfacial tension between two liquids, a liquid and a gas, or a liquid and a solid. The word ''surfactant'' is a Blend word, blend of "surface-active agent", coined in ...

catalyst Catalysis () is the increase in rate of a chemical reaction due to an added substance known as a catalyst (). Catalysts are not consumed by the reaction and remain unchanged after it. If the reaction is rapid and the catalyst recycles quick ...

, and blowing agent.

Advantages and disadvantages

Reaction injection molding can produce strong, flexible, lightweight parts which can easily be painted. It also has the advantage of quick cycle times compared to typical vacuum cast materials. 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 expenditure Capital expenditure or capital expense (abbreviated capex, CAPEX, or CapEx) is the money an organization or corporate entity spends to buy, maintain, or improve its fixed assets, such as buildings, vehicles, equipment, or land. It is considered ...

s. Another advantage of RIM processed foam is that a high-density skin is formed with a low-density core. The disadvantages are slow cycle times, compared to injection molding, and expensive raw materials.

Tooling

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

References

External links

examples of reaction injection molding products
* using Reaction moulding for Medtech and Medical Device

{{DEFAULTSORT:Reaction Injection Molding Injection molding