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Demands in the marketplace have led to the development of lightweight polyurethane elastomer systems for automotive fascia. These products can offer the automotive fascia molder the advantages of RRIM (reinforced reaction injection molding) polyurethane elastomers in a very competitive package. Current refinements developed in filler packages now allow for the application of reinforced RIM systems which exhibit improved surface quality. Moreover, the use of any of a variety of microspheres offers control of shrink and green strength of molded parts. These microspheres may be solid or hollow, rigid or flexible, and range in size from 1 micron to 300 microns. All of these systems exhibit processing characteristics similar to those of established RRIM products, pass on-car performance tests, and compete successfully with competitive lower-cost fascia materials.

Reaction Injection Molded (RIM) Polyurethanes are well-suited to automotive fascia applications. Their excellent impact resistance, paintability, and styling capabilities are well known. Efforts are underway in the automotive industry to improve the production economics associated with manufacturing RIM fascias. One method of reducing fascia material costs is to reduce the density of the polymer. This paper describes new experimental RIM systems that can be molded at a reduced density, yet still pass current OEM requirements, including on-car impact tests. These experimental RIM systems combine new filler technology and new resin formulations. The material cost for this system is competitive (based on molded part cost) with all other current methods of manufacturing fascias.