RIM (Reaction Injection Molds)/Foam Molds

The RIM (reaction injection molding) process has many benefits over competing thermoplastic or other high tonnage moldings with respect to capital and tooling outlay. The molding pressures in RIM are fractional as opposed to injection-molding, resulting in lower capital equipment costs and related tooling. Depending on the part geometry and volumes, aluminum sand castings or aluminum billet materials used in the RIM molding process can provide significant cost savings for more expensive P20 steel thermoplastic molds.

Why Choose Castek?

Castek’s aluminum foundry allows us to provide “as cast” aluminum open or closed pour foam molds as an option for CNC-machined sand castings or aluminum billet molds. As a result, Castek can fit the best mold type for each application. Many of the final products are used in automotive soft trim, including:

  • Automotive carpet foam molds
  • Seat molds
  • Door bolsters and arm rest molds
  • Center console molds
  • Engine cover
  • Sound-deadening molds to reduce noise, vibration, and harshness (NVH)

Many of our Castek foam mold designs incorporate foaming the substrate or injection-molded good to the back side of the foam, a process commonly known as foam in place (FIP) tooling. This tooling option eliminates post-operation labor to glue the foam bun onto the substrate.

Castek designs and builds numerous foam mold types for different polyurethane densities and types, including:

  • Flexible foam systems
  • Rigid foams
  • Structural foams
  • LFI (long fiber injection)
  • Elastomers

Castek has several designs for accurate and positive shutoff between the foam cavity and the substrate. In some instances, a hard shutoff or parting line can be utilized. Depending on the part geometry and complexity, Castek incorporates soft seals or cord stock and rope seal shutoffs into the mold design to achieve a clean product at the parting line each and every time.

Many of the above applications demand aluminum molds of considerable size for consumer goods and other large urethane parts. The unique Castek aluminum casting process produces an excellent surface quality on the cavity mold. Castek can media blast or acid etch the finished mold surface to provide a variety of textures and surface aesthetics. This enhanced foundry process has allowed Castek to use CNC-machined aluminum sand castings in place of the more expensive aluminum billet process in certain applications.

Send us your part data or project outline and a knowledgeable Castek team member will contact you to discuss how we can help with your project »