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In the highly competitive area of automotive fascias, Miles has already launched a comprehensive program which will assure that Polyurethane RIM elastomers remain the material of choice. Building upon the design advantages of PU-RIM, Miles is working on several programs to reduce the molded fascia costs by developing novel chemistry, unique RIM-systems and enhanced productivity. In recent years it is established that Polyurethane RIM systems offer a full range of physical properties for a variety of performance requirements for fascias, body panels and body side moldings. Miles has developed systems which meet the existing requirements on a much more competitive basis. This paper will talk about the novel low density filler package in the Bayflex 110 system, the experimental Bayflex 95 fascia system, and the experimental Bayflex 180 high performance material as well as discussing design options and achievable productivity enhancements.

RIM polyurethanes are used extensively by the Automotive Industry for fascia and body trim applications. As with all manufacturing processes, some quantity of waste product is generated. In the case of RIM, it is mostly gates, runners, and imperfect parts. As the environmental and economic demands to recycle continue to increase, it will become more important that all options for recycling be exploited. In Europe, for example, the pressures to recycle are already great. Major European RIM molders are currently recycling in-house or supplying RIM waste materials to add value to other products. This will most certainly also be the situation in the United States in the not too distant future. There are several technically viable methods to recycle RIM. These include adhesive molding, compression molding, chemolysis, pyrolysis, and 3 stream technology, One of the most recent methods of recycling RIM is just being put into production at European RIM molders.

New thermoset polyurethane polymers for automotive body panels can replace steel, SMC, and thermoplastics. These new materials offer short cycle times, thin wallstock, high temperature post mold processing, excellent durability, and new levels of productivity. Two new materials have been developed. One is a high-performance polyurea system that allows for oven bakes up to one hour at 190°C. The other is a high performance polyurethane developed for thin wallstock applications that has established new levels of productivity in the manufacture of rocker panels, fascia, and side moldings in Europe. The quality of these polymers is such that high productivity via robotic demold and trimming has been demonstrated. The durability of both these products is evident from the point of demold when the part exhibits an unprecedented toughness. Tight parameter control via a computer-based Expert System®1 improves cycle times, monitors manufacturing, and reduces scrap.