RIM (Reaction Injection Molding) for Gatan

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RIM (Reaction Injection Molding) for Gatan

Gatan, Inc. took a very hard look, and applied a very sharp pencil, when analyzing the cost of producing parts in Cast Urethane.  “It was just costing us a fortune…” offers John Duffy, Materials Manager SP&H, Supply Chain, Gatan, Inc.

The decision to use RIM was simple.  The RIM Process provided important values: Unlimited Mold Life, Higher Tolerance, More Robust Parts, and Significantly Lower Cost. When the time came to shift production of the company’s premier parts to the new process, research lead Gatan to Kenilworth, New Jersey, and the expertise of one of the country’s leading RIM manufacturers of first-class plastic instrument housings.

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“I didn’t know that.”

“I didn’t know that.”

Dozens of top industrial designers and mechanical engineers visited us at the 2015 MD&M show in Philadelphia to learn more about Reaction Injection Molding.  As we talked about the design and production benefits that companies like Beckman Coulter, Canfield Scientific and Siemens Healthcare GmbH have discovered working in RIM with Exothermic Molding, the universal response was

“I didn’t know that.”

It seems they hadn’t discovered…

The reduced cost, improved accuracy, and enhanced cosmetics over thermoformed plastics like Becton Dickinson,

That Gatan had us reverse engineer cast urethane parts for RIM to reduce cost and improve part stability,

Sterilis Medical has chosen Exothermic Molding as the exclusive supplier of cost and design efficient RIM parts over injection molding and cast urethane for a new-to-market device that sterilizes medical waste and will revolutionize discard management in the healthcare industry, or

Honeywell Analytics has come to Exothermic with a part that requires the combining of solid elastomer RIM molded polyurethane, layered with a rigid low-density urethane foam, covered with a flexible integral skin polyurethane, and painted to a precise finish while encapsulating both stainless steel and ABS tubing.

They just didn’t know about the design flexibility, low volume production efficiency, and cost savings realized by producing in RIM.

They do now.

Case Study – Solidscape: The Evolution into RIM Casements

The Reaction Injection Molding of plastic parts exceeds Industrial Designers and mechanical engineering expectations as a quality driven, price alternative to many manufacturing processes — the most noteworthy of those methods being Thermoforming.  In an unpublished video interview with Mark Magee, Senior Design Engineer of the visionary 3D printing equipment manufacturer, Solidscape, Inc., a Stratasys company, Mark lends the benefit of his experience working in RIM, and tells how RIM has become the “go to” process when Solidscape manufactures its industry leading printers.

To learn more click here:  Exothermic Molding:  Solidscape Case Study

Welcome to 2015!

All is well at Exothermic Molding, thanks to all of our customers, suppliers, and employees. Our goals are to continually find ways to improve our processing methodologies in order to provide the highest quality services at the best possible price. Here are a few highlights from this past year:

ISO 9001 Certification Training – We continue to implement ISO 9001:2008 procedures in order to become a certified provider.

Our Customers – We are pleased to say that as our customer base expands, and we continue to be amazed by the diversity of our clients and their intriguing products.

Our Employees – We have added to our staff and increased our production as necessitated by the marketplace. We have added personnel to our molding and painting departments, including a seasoned painting and finishing supervisor.

We initiated a cross training program whereby all employees have the opportunity to increase their value by learning skills in multiple production departments. This ensures our reliability as a supplier as we directly address constraints that normally occur in contract manufacturing workflow, while creating better, more engaging job opportunities and associated compensation.

Antonio Martinez, a 40 year veteran mold-maker at Exothermic, retires from full-time service with the company. Throughout his career with us, Antonio has made countless contributions to both customers and staff. His acquired expertise in RIM molding will continue to be available to us in a consulting capacity as we embrace the coming challenges of turning unique designs into reality. We thank Antonio for the invaluable contributions he has made to both our company and its employees.

Increased Production Capacity – We’ve installed new equipment to support our increased production requirements:
– Wet Technologies wet blast machine – our second unit is used in surface prep for painting. Investing in a second device ensures against production delays.
– Kaeser 30 HP air compressor system with associated purification devices to meet our increased demand for clean compressed air at 50 stations throughout the facility.
– Refurbishment of the Hurco Machining Center computing capability to allow for faster data processing and direct communication from our programming center.

Manufacturing Award – Caonabo Delgado, our Manufacturing Manager, was awarded the Next-Generation Leadership Award by NJBIZ for its inaugural New Jersey Manufacturing Awards event, held in conjunction with the New Jersey Manufacturing Extension Program. The ceremony honored producers of innovation including companies and professionals who create products and jobs in the Garden State.

Brand Development – Website update. New look. Enhanced user experience. Improved analytics. We’ve taken another step in our efforts to educate the market place about our capabilities and RIM Molding. Our new site provides easier access to data for process comparisons, case studies, and valuable white papers. Please visit us at www.exothermic.com.

As we move into this New Year, our company continues to focus on this most important business principal:

The only sustainable advantage in business is World-Class Customer Service, so we strive to provide excellent and reliable service every day.

Sincerely,

Paul K. Steck
President
January 2015

Exothermic Molding, Inc. Manufacturing Manager Wins Next-Generation Leadership Award.

FOR IMMEDIATE RELEASE

Caonabo Delgado represents the new face of manufacturing management in the United States as he captures award given as part of the New Jersey Manufacturing Awards 2014 celebration.

Kenilworth, New Jersey – October-2014

Caonabo Delgado, Manufacturing Manager for Reaction Injection Molding Company, Exothermic Molding, was awarded the Next-Generation Leadership Award by NJBIZ for its inaugural New Jersey Manufacturing Awards event  October 2014. The event, held in conjunction with the New Jersey Manufacturing Extension Program, honored producers of innovation including companies and professionals who create products and jobs in the Garden State.

caonabo w/ roamer arm

“I am honored and humbled to receive this recognition,” Delgado said.  “It is seldom that one is acknowledged for the hard work and insights that are part of managing and growing a small manufacturing company.  More importantly, this award sends a message to young talent considering a future career that manufacturing is alive, well and full of potential.”

Manufacturers and business leaders from all over New Jersey joined NJBIZ and NJMEP for the event as part of an agenda filled with activity making up the Third Annual National Manufacturing Day.  Delgado’s award is from one of ten award categories that day, and recognizes the individual who has demonstrated potential to make a significant impact as a leader in the future of New Jersey manufacturing.

“We are proud at Exothermic Molding to have Caonabo receive this honor.  It is a direct reflection of his contribution to the growth of our company, and plans for our future as a world class producer of goods,” observed Paul Steck, President of the reaction injection molding company.  “Caonabo’s acumen has been pivotal in making us a company whose customers recently rated us outstanding in several key metrics.”

Mr. Delgado’s education and career have been devoted to the manufacturing industry.  Attending Rutgers University, he graduated in 2004 with a Bachelor of Science Degree in Ceramics and Materials, later earning an MBA from DeVry University in 2008 while focusing his future on manufacturing management.  He has furthered his knowledge and efficacy by earning certifications in 5S, Lean Manufacturing, ISO, and Velocity Production Scheduling.

His influence on the company’s manufacturing practices yielded quantifiable results in the growth of Exothermic Molding.  Most importantly, he recognizes and rigorously advocates the manufacturing sector as a viable arena for progress and advancement.   Each year, for the past 13 years, he donates his time regularly speaking to students at the Union City High School about Engineering and the possibilities of a career in science and technology.

“I believe it is very important to give back to the community and let youth know that the future can be what they make of it,” he offers. “If I can get through to just one student about manufacturing, then I know that there will be one more person out there to keep the industry vital.”

When asked about his plans in manufacturing now that he has established this hallmark, he responds: “that’s simple – I am going to follow the advice of one of my mentors.  Always be a solution, not an obstacle.”

About Exothermic Molding Inc.

Exothermic Molding Inc. is one of the pioneers in the RIM Molding industry, The company was founded circa 1972 to provide Reaction Injection Molded (RIM) parts to the medical, electronic, and lab instrument market. Since then Exothermic Molding has expanded into many other applications and markets but remains committed to the RIM Molding process.

The company operates a state-of-the-art facility with modern computerized Programmable Logic Controlled machinery and remains at the forefront of RIM manufacturing.

Media Contact

Joseph Passarella
Marketing Manager

Phone:  908.272.2299

Email address:  joe@exothermic.com

RIM Molding vs. Urethane Casting (Rubber Molds)

Both Reaction Injection Molding and Urethane Casting offer a good deal of design freedom, including the ability to mold-in features and encapsulate materials.  They differ in the fact that only RIM allows for part design with significant wall thickness variations—typically from .125″ to 1.125″ in the same part.

RIM as well as urethane casting can be used to encapsulate a variety of materials, from metals to electronics. Each also produce a high quality finish, and take paint, silk screening and texturing well for improved branding.

Urethane casting in silicone rubber molds is often the more cost-effective choice for small production volumes, but rubber molds have a limited cycle life and long-term production can become cost prohibitive compared to RIM. Both processes are appropriate for producing molds for quick turnaround.

The initial tooling costs of urethane casting are lower than that of RIM. Tooling modification is also very cost-effective, but when aiming for production parts, RIM becomes the better choice cost-wise.

OTHER DESIGN CONSIDERATIONS: Many companies utilize rubber molds for years prior to converting to more permanent tooling, which can end up being extremely expensive. Because RIM can bridge the gap between prototype and production with parts that are precision molded instead of fabricated or cast, it can actually be most cost effective to utilize RIM in lieu of rubber molding.

Want to Save Money? Want to Save Time? This could be The Answer.

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“The Value of Strategically Sourced Sub-Assembly.”

Our new white paper describes how Strategic Sourcing of Value-Added Assembly provides benefits that address the ongoing need for efficiency in the manufacturing process.

The sourcing of components and the sub-assembly of products provides a wide array of advantages in several distinct areas:
(a) Cost Savings on Assembled Items
(b) Improved Material Flow
(c) Improved Quality
(d) Increased Flexibility Meeting Customer Demand
(e) Positive Environmental Effect.

Although all manufacturing processes differ to some extent, outsourced sub-assembly of parts produces measurable positive effect.

The benefits of sub-assembly materialize as reduced or eliminated labor costs, time saving, overhead containment, condensed part count, reduced part defects, and easier part replacement. Sub-assembly helps avoid costly line slowdowns and empowers your line with an enhanced ability to respond quickly to changing delivery demands and requirements. Sub-assembly creates fulfillment flexibility while decreasing operating costs.

Download this document from our website at www.exothermic.com.

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