Reaction Injection Molding Applications and Parts
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AdvancTEK uses reaction injection molding (RIM) to produce large, lightweight plastic parts in low-to-medium volumes, with design flexibility that competing processes cannot match at the same tooling investment.
From rigid interior panels to soft-touch armrests to high-impact exterior fascias, RIM covers a wide range of reaction injection molding parts across commercial vehicle, construction, agriculture, marine, and powersports applications.
Common RIM Parts and Components
RIM fits a specific window: parts too large or too low-volume to justify injection molding tooling, but complex enough to need design freedom on both the A-side and B-side. AdvancTEK produces three main categories of reaction injection molding products:
- Interior components (IVCR system) – These include cabinets, instrument panels, door panels, closet doors, and drawers, in sizes up to 40″ x 80″. They are typically finished with a vinyl cap or thermoformed skin.
- Soft-touch parts (Integral Skin / I-Skin) – These include armrests, center console caps, door-panel accent panels, and bump pads, normally 24″ x 40″ or less. Any part an operator touches often is a strong I-Skin candidate.
- Exterior and impact-resistant panels (MCU system) – These include fenders, body panels, exterior cladding, fender linings, and impact-resistant bumpers and fascias. A reaction injection molding bumper or front fascia, such as those on delivery-truck fronts, is a typical MCU application. AdvancTEK has produced components up to 36″ x 120″.
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Industries Best Suited to RIM
The best applications for reaction injection molding are in markets that run low-to-medium volumes (500–10,000 units) and need large, complex parts:
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RIM also extends to medical applications where soft-touch, encapsulated, or large-format parts are needed.
The Three RIM Systems
AdvancTEK runs three distinct polyurethane foam systems, each tuned to a different part requirement:
| System | What it is | Wall thickness | Density | Hardness | Best for |
|---|---|---|---|---|---|
| IVCR (improved vinyl clad rigid) |
Rigid foam system, usually finished with a vinyl cap or thermoformed skin | ~0.400″–0.500″ | ~20 lb/ft3 | Rigid | Interior structural and trim components |
| I-Skin (integral skin) |
Soft-touch skin with good wear resistance | 0.5″–2″ | ~14.7 lb/ft3 (nominal) | ~28 Shore A | Operator-contact soft-touch parts |
| MCU (microcellular urethane) |
Dense, tight-cell, high-impact system that looks close to an injection-molded part | ~0.200″–0.250″ | ~64.5 lb/ft3 | High impact | Exterior, impact, and wear-exposed parts |
⚠Note: Cross-sectional wall thickness from 0.25″ to 1.125″ is achievable within a single molded part; localized sections up to 1.50″ are possible.
Why Choose RIM for These Parts
When a part is weighed against injection molding or thermoforming, the trade-offs break down like this:
| Compared to | How RIM compares | When RIM is the right call |
|---|---|---|
| Injection molding | Higher piece price, but a far lower tooling investment | Larger parts at volumes where an injection mold cannot be justified |
| Thermoforming | Costs more in tooling | The part needs B-side geometry and greater design freedom |
– Patrick McAllister, AdvancTEK
Finishing and Value-Added Services
A-surface options include:
- Color-matched vinyl caps in a range of textures and colors
- Thermoformed skins that mimic woodgrain, sheet metal, or carbon fiber
- Painted finishes using urethane-based paint for a durable chemical bond and UV stability on exterior and marine parts.
Non-cosmetic parts can ship as bare substrate.
Beyond molding, AdvancTEK adds:
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Frequently Asked Questions
What parts are best suited to reaction injection molding?
The most common RIM molded products are large, complex parts in low-to-medium volumes – interior panels, soft-touch armrests and consoles, and exterior panels, fenders, bumpers, and fascias.
What production volumes make sense for RIM?
RIM is a medium-volume process, typically 500–10,000 units per year, with a sweet spot around 1,000–5,000.
When should I choose RIM over injection molding?
When the part is large, the volume is too low to justify injection mold tooling, and you still need design flexibility. The bottom line: RIM tooling costs a fraction of a comparable injection mold.
Are RIM parts suitable for outdoor use?
Yes. A urethane-based painted A-surface provides UV stability for exterior and marine parts, and the MCU system offers high impact resistance for exposed applications.