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LD-SRIM process technology, which can be readily tailored to match material physical property requirements to end-use applications, is answering the interior trim automotive engineers call for high quality, durable and cost-effective low weight composites. Due to their versatility, LD-SRIM composites, produced by reinforcing a water-blown MDI polyurethane foam matrix with a non-woven fiberglass mat, are successfully displacing PP and ABS thermoplastics, as well as wood fiber composites, in a wide variety of interior trim substrates. The technology's benefits, such as the ability to produce low weight parts (down to 0.27 g/cc for door panels) via pour-in-place techniques, and recent developments in internal mold release (IMR) formulations, have resulted in dramatic growth as demonstrated by its use in an expanding number of North-American produced vehicles.

TDI Polyurethane foams were first used in the automotive industry for seating and interior trim in the mid 1950's. Polymeric MDI achieved in the 1960's some usage in seating in relatively low TDI blends (15-25%). Significant advances have now been made in the application of all-MDI based flexible foam to yield more durable and comfortable parts. Interest in all-MDI flexible foams for trim parts such as headrests and sound insulating carpet underlay is also increasing. This paper presents a brief overview of all-MDI flexible foams and how they can meet the specifications of many automotive seating and trim applications.