Reaction Injection Molded (RIM) Polyurethanes are well-suited to automotive fascia applications. Their excellent impact resistance, paintability, and styling capabilities are well known.Efforts are underway in the automotive industry to improve the production economics associated with manufacturing RIM fascias. One method of reducing fascia material costs is to reduce the density of the polymer.This paper describes new experimental RIM systems that can be molded at a reduced density, yet still pass current OEM requirements, including on-car impact tests. These experimental RIM systems combine new filler technology and new resin formulations. The material cost for this system is competitive (based on molded part cost) with all other current methods of manufacturing fascias.