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RIM polyurethanes are used extensively by the Automotive Industry for fascia and body trim applications. As with all manufacturing processes, some quantity of waste product is generated. In the case of RIM, it is mostly gates, runners, and imperfect parts. As the environmental and economic demands to recycle continue to increase, it will become more important that all options for recycling be exploited. In Europe, for example, the pressures to recycle are already great. Major European RIM molders are currently recycling in-house or supplying RIM waste materials to add value to other products. This will most certainly also be the situation in the United States in the not too distant future. There are several technically viable methods to recycle RIM. These include adhesive molding, compression molding, chemolysis, pyrolysis, and 3 stream technology, One of the most recent methods of recycling RIM is just being put into production at European RIM molders.

The success of reaction injection molded vertical body panels for the Pontiac Fiero has encouraged future applications of synthetic body panels. The desire to further improve both part quality and productivity requires additional improvements in materials technology. Polyurea RIM is one technology which has shown the potential for an improved property profile. Previous “conventional” polyurea systems have been limited, however, in flow time, process latitude and shrinkage control. This paper summarizes the improvements provided by Bayflex 150 IMR, a flowable multiple-release polyurea RIM formulation. It provides an excellent combination of multiple release and physical properties, but overcomes the limitations of previous polyurea systems. Its overall performance characteristics should make it the best candidate for new body panel applications.