Getting Started With RIM - Transfer Existing Molds

When transferring your existing RIM molds to Exothermic, our engineering team implements a comprehensive process to ensure production continuity and maintain your quality standards. We begin with our New Transfer/Mold Checklist, a detailed protocol that captures all critical information about your tooling and production requirements. 

This systematic approach allows us to align our capabilities with your specific needs from day one.

Material Capabilities

Exothermic offers a comprehensive range of RIM materials to match your production requirements. Our material portfolio includes standard polyurethane systems 726 and 728, which provide an excellent balance of properties for general applications. We offer CM200 composites that deliver superior strength and durability for enhanced performance requirements. Our DCPD formulations address specialized needs for impact resistance and dimensional stability. Each material undergoes rigorous qualification testing to ensure it meets your specifications.

Advanced Finishing Capabilities

Our state-of-the-art finishing department delivers exceptional surface quality across various requirements. We specialize in automotive-grade paint systems that meet the most demanding OEM specifications. Our decorative finishing capabilities include precision screen printing and image transfer decals, allowing us to match your existing aesthetic requirements. Each finishing process follows documented protocols to ensure consistent, high-quality results.

Press Compatibility

Our facility houses multiple press configurations to accommodate various mold sizes and production requirements. Our engineering team evaluates your tooling specifications during the transfer process to determine the optimal press setup. We consider factors such as clamp force, shot size, and material processing parameters to ensure seamless integration of your molds into our production environment.

Metrology Capabilities

Precision measurement and validation form the cornerstone of our quality assurance process. Our advanced 3D laser scanning technology enables comprehensive geometric validation of your parts. This technology lets us create detailed digital representations of your components, facilitating precise comparison against CAD data and original specifications. Our metrology capabilities support both first-article inspection and ongoing production validation.

Manufacturing Process Development

For each transferred mold, we develop a customized manufacturing process that addresses your specific part requirements. Our engineering team analyzes critical parameters including material processing conditions, cycle times, and quality checkpoints. We document each process step, creating detailed work instructions that ensure consistent production results. This systematic approach allows us to optimize the manufacturing process while maintaining your quality standards.

Product Qualification

Exothermic supports various product qualification requirements to meet your quality system needs. We have extensive experience with First Article Inspection Reports (FAIR), Production Part Approval Process (PPAP), and IQ-OQ-PQ validation protocols. Our quality team works closely with yours to understand and implement the documentation and validation procedures. We maintain detailed records of all qualification activities, ensuring transparency and traceability throughout the process.

Production Support

Our commitment extends beyond the initial transfer process. We provide comprehensive ongoing support throughout production, including process optimization, quality monitoring, and technical consultation. Our engineering team remains engaged with your program, offering expertise in material science, design modifications, and continuous improvement initiatives. Regular production reviews ensure we maintain the highest standards of quality and efficiency.

Secondary Operations

Our in-house secondary operations capabilities ensure seamless integration of post-molding processes during tool transfers. When transferring existing tools, we can utilize your current fixtures for operations such as through holes, countersinks, and window openings, maintaining production consistency. Our machining expertise allows us to replicate or enhance existing fixtures as needed, ensuring the continuity of your established processes. Performing these operations in-house provides greater control over quality and lead times while maintaining your part specifications.

3D Printing Capabilities

Exothermic's advanced 3D printing capabilities support tool transfer projects through rapid fixture production and part validation. Our in-house FFF printers, capable of producing carbon fiber and fiberglass reinforced components, enable quick replicating existing fixtures and the creation of new tooling aids. Additionally, through our strategic partnership, we offer DCPD resin printing services, with plans to bring this capability in-house. These capabilities prove particularly valuable during tool transfers, allowing us to address fixture needs and validate process improvements quickly.

Value Added Assembly

Exothermic's value-added assembly capabilities provide a seamless transition for your existing assembly operations. Our facility is equipped to handle complete enclosure assembly and integration of supplemental components, including electronic systems. 

When transferring production, we can maintain your current assembly processes while identifying opportunities for optimization. By consolidating molding and assembly operations under one roof, we eliminate transportation costs, reduce handling damage, and streamline quality control. This integrated approach typically lowers labor costs, shortened production cycles, and improved quality metrics for transferred programs.

Contact our engineering team to begin your mold transfer process. We'll provide a detailed assessment of your tooling and develop a comprehensive transfer plan tailored to your production needs.