RIM Materials

At Exothermic, our revolutionary polyolefin thermoset systems deliver what was previously thought impossible: combining high-temperature stability with exceptional toughness while being 7-10% lighter than traditional alternatives. 

From our partner NZT Group, Inc. and their advanced NEOZANT™ (Poly-DCPD) offering superior chemical resistance and durability to Baydur's high-density structural foam systems meeting rigorous UL94 V-0 standards to Prism's sophisticated polyurethane systems with exceptional surface finish—our materials aren't just meeting industry demands, they're redefining what's possible in plastic part production.

Whether you need parts with exceptional impact strength, superior environmental resistance, or precise electrical insulation properties, our cutting-edge material portfolio, backed by Nobel Prize-winning research, is engineered to deliver performance that consistently outperforms conventional solutions across aerospace, medical, defense, and industrial applications.

• Poly-DCPD

• Baydur® 726 IBS

• Baydur® 728 IBS

• Prism® CM-200

Poly-DCPD

Reaction Injection Molding or RIM, is a manufacturing process particularly well-suited for PDCPD. RIM allows for the production of large, complex parts with excellent surface finish and consistent properties.

PDCPD resin systems achieve what was previously considered impossible in thermoset materials - combining high-temperature stability with exceptional toughness. This breakthrough enables new possibilities in thermoset materials, particularly for high-throughput component production requiring superior performance characteristics.

The technology's innovative formulation creates polymers that consistently outperform conventional solutions while maintaining processing compatibility with existing equipment.

Based on cradle-to-gate analyses, the PDCPD resin system delivers significant environmental advantages, with a carbon footprint approximately 60% lower than epoxy resins and nearly 50% lower than vinyl ester resins.

This combination of enhanced performance and practical implementation makes PDCPD resin systems a transformative solution for modern manufacturing challenges.

This revolutionary technology represents the future of industrial materials, allowing manufacturers to meet increasingly demanding performance requirements while improving production efficiency and reducing overall costs.

Strengths:

• Superior strength-to-weight ratio (7-10% lighter than alternatives), high impact and fracture toughness, excellent fatigue resistance.

• Exceptional chemical, environmental, and corrosion resistance; low water absorption for dimensional stability; hydrophobic properties.

• Wide operating temperature range (including high temps above 120°C and cryogenics), high compressive and abrasion resistance, minimal shrinkage/warping.

• Lower carbon footprint (60% less than epoxy, 50% less than vinyl ester); enables complex geometries and fast cycle times in RIM processing.

• Can achieve compliance to UL94V0 with an additive (4mm wall thickness required).

• Can achieve ballistics rating with added fiber reinforcement.

Applications:

• Automotive (body panels, bumpers, truck/agricultural components), construction (heavy equipment, protective housings), infrastructure (pipes, tanks), recreational vehicles (RVs, boats), wind turbine blades, electric vehicles, aerospace, and defense.

Examples for When to Use:

• Opt for lightweight, durable parts exposed to impacts or harsh environments, such as automotive bumpers or wind turbine blades needing corrosion resistance and fatigue performance; ideal for large, complex structural components where weight reduction improves efficiency.

 

Baydur® 726 IBS

Baydur 726 IBS significantly advances high-density polyurethane structural foam systems engineered explicitly for reaction injection molding (RIM) processes. This innovative system features a specialized interactive blowing system (IBS) comprising two reactive liquid components working harmoniously.

The system's first component (Component A) combines a modified polymeric diphenylmethane diisocyanate (PMDI) prepolymer blend, while Component B features a carefully formulated polyol system. Notably, this environmentally conscious formulation contains no CFC or HCFC-blowing additives.

Particularly valuable in the electronic, equipment housing, and appliance markets, Baydur 726 IBS meets rigorous safety standards with its UL94 flammability rating of V-0 and/or 5VA. Manufacturers choose this system for its exceptional strength, superior surface finish, and ability to produce large parts effectively.

Strengths:

• High-density structural foam with interactive blowing system (IBS) for excellent strength, superior surface finish, and large-part molding capability.

• Meets UL94 V-0 and 5VA flammability ratings; short demolding time (1-1.5 minutes), high tensile strength (around 21 MPa), chemical resistance (acid/alkali), and good high-temperature performance.

• Free of CFC/HCFC blowing agents; enables low-volume production of complex panels.

Applications:

• Electronics (housings), equipment enclosures, appliances, and structural foam parts in life sciences or low-volume manufacturing.

Examples for When to Use:

• Choose for flame-retardant electronic housings or appliance components needing quick production cycles and smooth finishes; suitable for larger structural panels where safety standards like UL94 V-0 are mandatory and chemical resistance is beneficial.

Baydur® 728 IBS

At the forefront of manufacturing innovation, Baydur 728 IBS is a cutting-edge high-density polyurethane structural foam system developed specifically for reaction injection molding (RIM) applications. This sophisticated material leverages an interactive blowing system (IBS), delivered through a dual-component reactive liquid system that ensures precise, controlled results.

The chemistry behind Baydur 728 IBS is carefully engineered. Its primary component utilizes an advanced modified polymeric diphenylmethane diisocyanate (PMDI) prepolymer blend, complemented by a specialized polyol system as the secondary component. In keeping with modern environmental standards, the formulation achieves its performance goals without relying on CFC or HCFC-blowing agents.

In the demanding world of electronics, equipment housings, and appliances, Baydur 728 IBS excels by meeting the stringent UL94 V-0 and 5VA flammability ratings. This material has become a go-to choice for manufacturers who require exceptional structural strength, flawless surface quality, and the capability to produce large-scale components.

Strengths:

• High-density structural foam with advanced IBS for exceptional structural strength, flawless surface quality, and large-scale component production.

• Achieves UL94 V-0 and 5VA flammability ratings; outstanding flow properties, mechanics, and toughness for heavy-duty use; no CFC/HCFC agents.

• Specialized formulation supports high-performance RIM processing with good paintability and adhesion.

Applications:

• Electronics, equipment housings, appliances, construction (e.g., concrete production boards), and heavy-duty structural parts.

Examples for When to Use:

• Use for demanding appliance or equipment enclosures requiring superior flame retardancy and surface aesthetics; ideal for heavy-duty applications like construction boards where high toughness and large-part capability outweigh basic foam needs.

Prism® CM-200

Prism CM-200 represents a sophisticated solid polyurethane system engineered specifically for reaction injection molding (RIM) applications. This advanced system features an integrated internal mold release (IMR) and operates through a two-component reactive system that ensures consistent, high-quality results.

The material's chemistry combines a polymeric diphenylmethane diisocyanate (MDI) as Component A with a specially formulated polyol blend as Component B. Together, these components create a system that achieves the demanding UL94 V-0/5VA flammability rating, making it ideal for electronic applications, equipment housings, and appliance manufacturing.

Manufacturers consistently choose Prism CM-200 for its outstanding combination of structural strength, exceptional surface finish quality, and ability to produce large-scale components effectively.

These properties have established it as a preferred solution in industries where performance and aesthetics are equally critical.

Strengths:

• Solid polyurethane system with integrated internal mold release (IMR) for easy demolding, outstanding structural strength, exceptional surface finish, and large-part capability.

• UL94 V-0/5VA flammability rating; good thermal, electrical, and chemical resistance; suitable for RIM with two reactive components (MDI and polyol blend).

• Enables acoustical insulation and precise molding of complex shapes without foaming agents.

Weaknesses:

• Moisture-sensitive like other urethanes (requires dry storage); user testing needed for specific applications, as performance can vary; potentially less flexible than foam variants for impact absorption.

Applications:

• Electronic devices, equipment housings, appliances, and solid structural components in manufacturing.

Examples for When to Use:

• Select for solid, non-foam parts in electronics needing high flame retardancy and premium surface quality, such as device casings; best for applications prioritizing rigidity, aesthetics, and safety over lightweight foaming.