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The technologies of recycling Reaction Injection Molded (RIM) polyurethane polymers have been refined to the stage of commercial reality. Chrysler Corporation is in the process of qualifying the use of automotive fascia containing recycled RIM thermoset polymers. This will mark the first use, in North America, of a recycled RIM thermoset polymer into a class A surface exterior automotive part. This was made possible through a close working relationship with Polyrim Green Lane, a division of Decoma International, and Dow Plastics. The described process technology allows the recycle of painted and unpainted process scrap, and potentially post consumer scrap, into the same application without the loss of surface quality or polymer performance. This will divert these materials from the waste stream that is currently being landfilled.

A simple and economical process has been developed that allows the recovery of scrap RIM thermoset polymer generated in the manufacturing of fascia, body panels and other parts. This process consists of a size reduction process of the thermoset polymer into a very fine powder and it's subsequent incorporation into virgin raw materials. Original polymer performance and surface quality are maintained. This “regrind” process provides positive environmental and economical effects to molders of RIM polymers.

Two new RIM polymers for fascia have been developed which provide significant improvements in processing and performance over commercial polyurethane/polyurea fascia systems. These polymers combine improved filler technology with new chemistries to yield a painted surface quality within five “DOI” units of steel, and they exhibit improved dimensional stability, without sacrificing low temperature impact strength. Compositional modifications of polyurethane precursors provide these benefits in polyurethane/polyurea (PU/UREA) RIM polymers. This chemistry yields high performance fascia desired by the automotive industry. Polyurea RIM systems, adapted from body panel technology, provide these same desirable characteristics and additionally offer the potential for self-release unassisted by external mold release agents. The increased cost of polyurea RIM chemistry is partially compensated by higher productivity.