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The use of low density reinforced Reaction Injection Molded (RIM) substrates for covered interior automotive articles continues to increase globally. Reduced party mass, consolidation of manufacturing steps (labor), and the use of aluminum tooling, instead of steel, are cited advantages that LD-RIM offers when compared to traditional wood based and thermoplastic materials. Two RIM processes are successfully being used to produce covered interior door panels. Low density structural RIM (LD-SRIM), utilizing conventional RIM equipment, involves the placement of a pre-cut fiberglass mat in the tool cavity prior to open-pour injection of the 2-stream liquid urethane components. Low density reinforced RIM (LD-RRIM), utilizing lance cylinder RIM equipment, incorporates reinforcing fibers, such as milled fiberglass or wollastonite, in the liquid resin component. The liquid resin containing reinforcing filler is injected with the isocyanate component into a closed mold.

Lightweight reinforced RIM polyurethane substrates are increasingly being specified for fully covered automotive applications such as interior door panels, instrument panels, and package shelves. In addition to offering a 30-40 % weight reduction over conventionally used substrate materials, consolidation in manufacturing steps are achieved by molding direct to polyvinylchloride (PVC), polyurethane (PU) and/or textile coverings. Weight reduction and consolidation of manufacturing steps lead to considerable part cost savings. Styling trends toward complex, deep drawn door panels, integrated with instrument panel modules, are easily fulfilled with low pressure RIM. Existing RIM capital used to produce RRIM fascia, cladding, and body panels is suitable to manufacture low density RRIM substrates (LD-RRIM).