When a manufacturer of advanced virtual reality-enhanced treadmills needed to combine durability with aesthetic excellence, they turned to us, Exothermic, the leader in reaction injection molding (RIM) technology.
The challenge? Creating side panels that could withstand daily use while maintaining a premium appearance worthy of high-end fitness centers and physical therapy facilities.
"In the fitness equipment industry, especially at the premium end, appearance matters just as much as performance," says Paul Steck, President of Exothermic Molding. "These treadmills represent a significant investment for facilities, and every component needs to reflect that quality."
The project's focal point was the creation of trapezoid-shaped side panels, spanning approximately four feet vertically from the treadmill platform to the arm guards. These prominent visual elements demanded a material solution that could deliver on multiple fronts: structural integrity, weight optimization, and superior surface finish.
After extensive prototyping and production planning, Exothermic selected Poly-DCPD (Dicyclopentadiene) chemistry for the panels. "Poly-DCPD is exceptionally strong, works at high temperatures, and leaves no sink marks," explains Steck. "Its low viscosity allows for faster processing than conventional resin systems. This results in better mold fill and the ability to use less expensive molds."
The material choice builds on groundbreaking chemistry developed by Nobel laureate Dr. Robert Grubbs, whose Ruthenium catalyst technology revolutionized thermoset resins. The technology's development earned Dr. Grubbs the Nobel Prize in chemistry, and he later co-founded Materia Inc. to commercialize these advanced resins.
Exothermic's commitment to innovation extends beyond material selection. The company recently invested in custom equipment specifically designed to process Poly-DCPD chemistry, demonstrating our dedication to pushing the boundaries of RIM technology. This investment builds on its historic position as the first company in the United States to employ the RIM process, dating back to our establishment in 1971.
"The material minimizes surface anomalies like pitting and requires less finishing work," Steck notes. "When you're producing premium components for high-end equipment, this kind of efficiency doesn't just save time – it ensures consistently superior results."
Specially formulated for high-performance applications, Poly-DCPD thermosets are engineered to compete with and potentially replace traditional resins, including epoxy, vinyl ester, and polyester variants. The material's adaptability to industry-standard manufacturing processes makes it particularly valuable for manufacturers looking to upgrade their material solutions without completely overhauling their production methods.
Exothermic's expertise in producing shorter runs of highly designed parts with specialty finishes positioned us perfectly for this project. Our early adoption of Poly-DCPD chemistry and investment in specialized processing equipment demonstrates our company's ongoing commitment to advancing RIM technology for demanding applications.
The successful implementation of Poly-DCPD chemistry in this high-end treadmill application showcases how innovative material science can meet the demanding requirements of premium fitness equipment, where performance and aesthetics play crucial roles in market success.