Using advanced Thermoset technologies, our Design and Product Engineers at Romeo RIM can be an extension of your Design and Engineering teams. This guest engineering value added service allows for Design for Manufacturability when done in the early stages of the design phase. Our low cost competitive tooling can provide a significant tooling investment savings based on the application.
Our years of knowledge and experience of Polyurethane and Dicyclopentadiene (DCPD) processing include: Reaction Injection Molding (RIM), Long Fiber Injection (LFI) / High Gloss LFI (HGLFI), In-Mold Paint (IMP), and more!
Reaction Injection Molding “RIM“
Raw Materials used are Polyurethane Elastomers, Structural Foam, Reinforced RIM (RRIM), Structural RIM (SRIM), and DCPD
Reaction Injection Molding (RIM) is a process where two liquid components are injected into a tool and chemical reaction between the liquids results in a solid plastic part being formed. Materials that can be Reaction Injection Molded are typically polyurethanes where the two liquids are isocyanate and polyol, or Dicyclopentadiene (DCPD) where the two liquids are monomers.
Our ISO-compliant, low-viscosity RIM services provide parts with a variety of unique product benefits, including Class A surfaces, wall thickness changes, high impact resistance, encapsulation of inserts, and in-mold coatings. We are the largest company in the world that provides In-Mold Paint services and produce the largest parts available in North America.
Long Fiber Injection “LFIComposites
High & Low Gloss LFI
In 1999, Romeo RIM was the first company to bring a new material technology to North America called Long Fiber Injection (LFI) which is a sprayed slurry into open mold based on simultaneous pouring of Polyurethane resin together with chopped fiberglass at various lengths (1/4” to 2”). LFI is a new production technology, wherein a robot is used to spray a mixture of polyurethane and chopped fiberglass onto a mold, which then uses low compression to form the part, such as roofs and body panels. This process is similar to SRIM, but in this molding operation, the original two-step method is condensed into a single-stage procedure that is robotically applied.
Our LFI operations provide parts with several product advantages, including lower tooling and production costs, dimensional stability, and optimized weight and strength – among other benefits. From mass transit to agriculture and construction, our ISO-compliant LFI services have met the needs of multiple industries.
Excellent Stiffness-to-Weight Ratio
Class “A” High Gloss Finish (UV Stable)
Chopped Glass Reinforcement 0-40% by Weight
65 PCF (1.02d) – 83 PCF (1.33d)
Ability to Modify (on the fly) and Localize Density
Low CLTE
Dimensionally Stable
High Impact Resistance
Large Complex Parts
“B” Side Details (Molded-In Ribs, Bosses, Inserts, etc.)
12′ x 12′ Double Shuttle System (The Largest LFI Press in the World)
Romeo RIM was among the first RIM companies to commercialize In-Mold Painting during the 1980’s. “IMP” involves painting the cavity of the tool immediately prior to injecting the Polyurethane (Iso/Poly) material with or without Chopped Glass. During the molding process the paint chemically bonds to the Polyurethane material thereby eliminating the possibility of the paint chipping or flaking off, which can occur with post-applied paint. In-Mold Painted surfaces perform just as well and/or better than post-applied painted surfaces because the chemical adhesion that becomes an integral part of the substrate. The finish part can range from Low gloss to a High Gloss Class-A surface finish. This allows the part to be directly packaged and shipped to the customer for assembly, if no secondary process is needed.
One of the largest costs of painting plastic parts is the prepping, painting and finishing process. This not only includes the cost of the paint and labor, but also overhead costs of additional painting equipment, drying ovens, environmental equipment, etc. Although IMP minimizes these costs, the greatest cost savings are achieved by processing efficiencies that eliminates post-mold painting steps such as cleaning, prepping, sanding, priming and improving first time run yields.
Advantages include:
Class “A” High/Low Gloss Finish (UV Stable)
Chemically Bonded
Excellent Adhesion between the Barrier Coat and the Substrate
Achieve any Color Finish
Capable of Flexing with the Part with No Results of Cracking or Crazing in the Part Surface
Excellent Orange Peel Finish
Post-Applied Paint
Post mold painting offers the added benefits of exact color matching to other parts and parts made of other materials. Post mold painting covers minor surface blemishes – dependent on the amount of solids in the paint formulation.
Compression Molding “SMC“
Ideal for high-volume composite parts where strength is a priority. This closed mold process is most common for Sheet Molded Compounds “SMC” and Bulk Modled Compounds “BMC” materials. In-Mold Coatings can be used to eliminate the need for primer and improve paintability.
Fiberglass Reinforced Plastics “FRP“
FRP is a composite material made of a polymer matrix reinforced with fibers. The fibers are usually glass, carbon, aramid, or basalt. FRPs are commonly used in the aerospace, automotive, marine, construction industries and ballistic armor. Ideal for rapid product development. The tooling fabrication process is simple and relatively low cost. The two processes used in FRP are Hand Lay-Up and Spray-Up. Our engineers will help determine which method is most suitable for your product.
Resin Transfer Molding “RTM“
RTM or Resin Transfer Molding is a closed mold process. In this process, matched male and female molds are being used. Before the process injection, fiber pre-form is placed in the mold cavity. Then the molds are clamped. Resin mix then is injected or transferred into the cavity through injection ports at a relatively low pressure. Generally used for components with large surface areas or complex shapes. Recommended for products that require high strength-to-weight ratios. RTM parts have 2 finished surfaces with a high glass-to-resin ratio.
