Resin Injection Molding

Resin Infusion is a composite manufacturing method that works very well for small to large flat plates as well as very large composite parts. Resin Transfer Molding (RTM) and Vacuum-Assisted Resin Transfer Molding (VARTM) combine the concept of resin infusion with either an open or closed mold. These methods are cost effective compared to operating an autoclave. The resin infusion process is a technique that injects the thermosetting resin systems (EP, PUR, UP) into one-piece molds (tools) using a vacuum. The dry fabrics (CFRP / GFRP) are fixed on the mold using a vacuum bag and then, usually at room temperature, impregnated with the resin system via vacuum. Resin infusion is the process whereby resin is drawn into a dry laminate whilst it is held under vacuum against a rigid mould by a sealed flexible membrane. The most commonly used membrane consists of a disposable film (vacuum bag) and this film is sealed against the mould edges using a sealant tape.

Resin infusion is particularly relevant when making very large structures as tooling costs are relatively low. Unlike RTM, the ‘B’ surface finish of the resulting laminate is not controlled cosmetically but excellent laminate properties can be achieved. Volatile emissions can also be dramatically reduced making resin infusion an excellent alternative to large-scale open moulding.
Resin infusion is the process whereby resin is drawn into a dry laminate whilst it is held under vacuum against a rigid mould by a sealed flexible membrane. The most commonly used membrane consists of a disposable film (vacuum bag) and this film is sealed against the mould edges using a sealant tape. Resin infusion is particularly relevant when making very large structures as tooling costs are relatively low. Volatile emissions can also be dramatically reduced making resin infusion an excellent alternative to large-scale open moulding.

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Benefits of RIM

Recent developments with renewable silicone vacuum membranes have widened the scope for resin infusion and can sometimes be used to reduce the general cost of consumable materials. Our extensive experience with vacuum infusion enables us to produce innovative and cost-effective parts for our OEM customers.
As the resin infusion process has become more widespread the need to mechanise the handling, mixing and delivery of the resin has become more important. The traditional technique of hand-mixing bulk resin becomes impractical and potentially risky when using the process on any significant scale. Problems with mixing consistency, potential bulk-exotherm and high levels of waste can have a significant impact on the viability of the process.

A meter-mixing machine can be used to simply dispense mixed resin ‘on demand’ into a suitable container but Composite Integration have taken the technology a step further by pioneering the development of systems capable of injecting ‘directly’ into the infusion process. With the use of In-mould pressure sensors (IMPS) positioned strategically in the mould, sending the information to the injection machine and enable the process to be completely ‘closed’ with fully automatic quantity and flow-rate control

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Advantages of ‘directly injecting’ includ

The process is best suited for mid-volume production in the range of 200 to 5,000 parts per year and yields products with high strength-to-weight ratio.