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Plastics play a huge role in manufacturing. They are present in virtually every industry. From automotive to medicine, plastic materials are utilized as end products and components for assembling a more complex product.

However, these plastic products are not readily available in the market, and they have to undergo a manufacturing process within a plant dedicated to designing and molding plastics.

RIM Manufacturing is an example, and helping to design and molding plastic end products or components is something we do exceptionally well. To give you a clear picture of what we do, we’ll compare the process we use, Reaction Injection Molding (RIM), with another popular plastic manufacturing method – thermoforming.

What Thermosetting & Thermoforming?

Let’s cover the basics.  Reaction Injection Molding is a Thermoset process whereby low-viscosity liquid polymers and isocyanates are mixed at high-pressure (2000 psi) and injected into temperature-controlled molds at low-pressure (150 psi).   An exothermic reaction occurs as the temperature of the liquids reach 350 degrees Fahrenheit before quickly cooling to become a solid polyurethane part. Thermoforming, on the other hand, draws a pliable plastic sheet stock down onto a heated mold.  A vacuum may be used to evacuate any air and accurately reproduce the details of the mold.

The key difference between the two is significant.  RIM (Thermosetting) allows for tight tolerances, unique design, and molded in ribbing and bosses.  Thermoforming, on the other hand, is good for simple design parts with limited functionality and cosmetic finish.

The Applications of Thermosets & Thermoplastics

The different qualities that thermosets and thermoplastics possess dictate where and how they may be applied.

For example, thermosets are ideal for products exposed to high temperatures because of their incredible heat resistance. For this reason, manufacturers use thermosets for the body and components of household and kitchen appliances. These machines tend to generate excess heat. If thermoplastics are used for these products, they could warp at best and melt and mess up the electricals at worst.

Thermoplastics, on the other hand, are ideal for single-use plasticware like cups, drinking bottles, food containers, and grocery bags. CDs, DVDs, children’s toys, sports equipment, and eyeglass lenses are also made from different thermoplastics.

Thermoset vs. Thermoplastic: Which Should You Choose?

Which is the better material to use for your products? The answer depends on the uses of your products. Our opinion at RIM Manufacturing, however, skews in favor of thermosets. We attest to the quality of thermoset plastic, and its heat-resistance and physical integrity are additional perks. More importantly, it’s easier for us to create intricate details like textures, irregular corners, and protrusions using reaction injection molding. Thermoforming is more acceptable for simpler designs.

Find out if thermoset plastics are compatible with your manufacturing requirements and product design. Talk to our product specialists at RIM Manufacturing. Contact us today.

Reaction Injection Molding (RIM) is a robust process used to produce polyurethane plastic parts by combining liquids (polyol and isocyanate) to form large, high-performing, lightweight parts used in manufacturing different products. Over the years, the process has become popular because of the design flexibility and cost-effectiveness when compared to other manufacturing processes.

The Advantages of the RIM Process

Apart from its affordability, the benefits of RIM Mold and Part Design are useful to our customers for the following reasons.

• Creation of Large Parts: RIM uses low viscosity polyurethane liquids, making it easier to create uniquely designed, large plastic parts without compromising performance.
• Highly Cosmetic Surface Finish: The process accommodates finer design details and surface finish to produce quality pigmented or in-mold painted parts.
• Variable Wall Thickness: The chemical reaction used to form parts is highly customizable, giving designers better control to vary wall thickness and eliminate sink marks.

All of these allow for the creation of high-quality, aesthetically pleasing, and long-lasting plastic parts. In choosing the RIM process in manufacturing your product parts, you join a select group of industries.

Industries that Utilize the RIM Process

It’s difficult to beat results, making the RIM manufacturing process highly sought-after. In the last few years, more businesses across many industries have made the switch to the RIM process. It has resulted in high-quality, high functioning, finished products.

Automotive Industry

RIM is widely used in the automotive industry. Most car manufacturers use it to create large parts, including bumpers, quarter panels, decorative trims, and wheel arch liners.  The durability and flexibility of hardened polyurethane provide these parts with ample tensile strength and shock resistance. Some automotive brands also use RIM to create whole prototypes for testing purposes and show cars for their showroom displays.

Heavy Equipment Industry

The heavy equipment industry uses the RIM process in creating intricate parts, specifically for heaters, mobile generators, and light towers. The polyurethane solution is resistant to corrosion and other forms of wear and tear, resulting in tough and low-maintenance parts. The process is also used for B-side geometry, in-mold paint, and molded-in inserts. All of these give designers better control in building the final products. 

Healthcare Industry

Although the RIM process is largely known for its ability to create large parts, the healthcare industry utilizes it to design and manufacture intricate parts for medical devices (e.g., ophthalmic enclosures for eye examination equipment). In some cases, the RIM process is used to make whole devices, such as an electronic spray system, a DNA analyzer, and a full-body analysis machine. Polyurethane plastic is also resistant to bacteria growth, making it a hygienic alternative to other materials.   

Partner with RIM Manufacturing for Your Next Reaction Injection Molding Project

Discover the advantages of using this innovative parts manufacturing for yourself. RIM Manufacturing, LLC, has over four decades of industry experience, giving us the expertise to meet different needs. Let us help you create the parts you need for your products – whatever they may be!

Get in touch with our team to learn more about our products and services.