Reaction Injection Molding (RIM), Resin Transfer Molding (RTM), Bulk Molding Compound (BMC) and Sheet Molding Compound (SMC)

CarverCompositesR3Previously R3 Composites in Muscatine Iowa

Metal Conversion Projects Where High Strength and Low Weight Are Critical

Prototype, Short run and Production

Reinforced plastics for structural parts with qualities of:

  • High strength, low weight parts
  • Corrosion resistance
  • Chemical Resistance
  • Heat Resistance
  • Fire Retardant
  • Weatherability
  • Colorfastness
  • Microwave Transparency
  • Weight Reduction
  • Variety of processes for short run, prototype and production (small, medium and large volumes)

Processes

  • Matched Die Molding
  • Resin Transfer (RTM) Option for closed molding. Two finished surfaces.
  • RTM is cost effective over labor intensive processes when quantities are sufficient to justify tooling.
  • Compression Molding Option for closed molding. Two finished surfaces. RTM is cost effective over APM or hand lay-up when quantities are sufficient to justify tooling. & Injection Mold Components
  • Bulk Molding Compound (BMC) Compression Molding
  • Sheet Molding Compound (SMC) Compression Molding
  • Reaction Injection Molding (RIM) Injected into a closed mold at low pressure
  • Prototyping and Design Services SLA and Software Analysis

Services

  • Prototyping and Design Services Engineering staff offers extensive experience from concept to new product completion.
  • Enhance your designs through
  • Computer generated SLS parts (sintered nylon)
  • Computer generated FEA structural analysis
  • Machined billets for testing and evaluation 3-D Cad solid models
  • Computational Fluid Dynamics (CFD)
  • 3-D Cad solid models
  • Accurate dimensional design
  • Computer generated SLS parts (sintered nylon)
  • Cast tooling from existing shapes / parts

Our experienced design team can enhance your designs through and Finite Element Analysis (FEA) software to simulate performance with accuracy and speed. We then can generate precise prototypes using stereo lithography (SLS) or m. Once you finalize and approve your product we can go to production using a Compression or Resin Transfer process.

Materials

  • Resin systems: Thermoset vinyl ester resins and urethane resins systems. Resins include bio-resin (30-50% soy & corn)
  • Reinforcement materials: The primary function of reinforcement material is used to enhance properties of the resins. Many types of fibers can be used for composites, including but not limited to, carbon, several types of glass (E, C, S or R, S2 or A), Kevlar ®, and natural fibers. These are available in mats and strands known as roving or twisted into yarn. The fibers may be stitched or woven into various 2-D or 3-D architectures. See examples of RTM reinforcement.
  • Core Materials: Foam, balsa Wood and Honeycomb cores and many more.
  • Colors: In mold color.

Typical Applications

  • Metal Casting Replacements
  • Electronic Sleeves
  • Compression Molded parts offer a alternative to die-cast, stamped or other formed metal parts.
  • Pumps
  • Probes
  • Fan Components
  • Fenders
  • Impellers
  • Doors
  • Wind Blades

Special MaterialsR3ConductiveEleR3Wear

  • High Wear Composites                                                                                                    
  • Extreme low weight Composites
  • Metalized CompositesR3Float

 

Information & News

  • Stiffness Comparison 3 Kb HTML

With an engineered, oriented composite structure, a crack will not propagate in the same manner as metal; the fibers act as "crack arrestors" and the loads find alternate resolution paths through adjoining fibers.