JEC COMPOSITES MAGAZINE - Issue #73 - June 2012 - 76

injection

The world’s largest long fibre injection moulding machine
Continuing its commitment to commercializing innovative composite technologies, Romeo RIM Inc. has installed the largest long fibre injection (LFI) press in the world, with the capability to produce very large parts measuring up to a record-breaking 11 square metres.

By
pAul conDeeliS vice preSiDent of BuSineSS Development romeo rim inc.

he LFI press and line were unveiled in May 2011 during an event at the company’s facility, located north of Detroit, and entered into production months ago. The new machine is a 400 ton, 3.7 x 3.7 m double-shuttle press. As a fully-automated system, it will ensure the consistency in production of all components. It is also noteworthy that it is the only piece of equipment in North America that will robotically in-mould paint parts. For nearly 30 years, Romeo RIM has provided customers with the latest, cutting-edge technologies and services to meet their production needs. For example, it was the first company in North America to install an LFI random injection moulding (RIM) system for serial production. This forward-thinking, customer-centric mindset continues to drive the business today. By installing this line, the company is able to give its customers a real competitive edge – the ability to produce very large parts that are strong, light and also cost-effective.

ting parameters set forth by Romeo RIM, representatives from Bayer MaterialScience LLC and KraussMaffei met frequently with the moulder during the development phase. KraussMaffei, inventor of the LFI process, designed and manufactured the press, and served as general contractor for the project. Bayer MaterialScience LLC, which has a long-standing working relationship with Romeo RIM, applied its expertise in polyurethane chemistry to the project.

A proven process
LFI is a proven process for producing large, strong and lightweight parts. LFI offers unique benefits, such as the ability to utilize lower-cost glass fibre rovings rather than mats, and the ability to use either a foamed or solid polyurethane formulation. During the process, long glass fibres are injected along with polyurethane resin in a one-step process. A glass fibre chopper

is attached to the polyurethane dispensing mixhead, which is attached to a robot. The robot is programmed to move over the open mould cavity while simultaneously dispensing both the long glass fibres and the polyurethane resin in an open-pour method. At the end of the pour, the mould is closed and the part is formed. A sprayable in-mould coating results in a painted, Class-A surface right out of the mould. Large, Class-A-surface LFI parts that can be produced with the new press are well suited for a number of markets, including agricultural, building and construction, mass transit and heavy trucks, among others. Companies that typically were forced to use steel, sheet-moulding compound (SMC) and aluminium now have a cost-effective and lighter alternative to parts made from these traditional materials. n
More information: www.romeorim.com

A collaborative effort
The design and installation of the press was a collaborative effort of Romeo RIM, materials supplier Bayer MaterialScience LLC and equipment maker KraussMaffei. To ensure the new LFI production line met the design requirements and opera-

Romeo RIM’s double-shuttle press

76 jec composites magazine / No73 June 2012

http://www.romeorim.com

JEC COMPOSITES MAGAZINE - Issue #73 - June 2012

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #73 - June 2012