The technology that we will develop will directly impact on the thermoplastic processing sector and more specifically the thermoplastic reaction injection moulding (RIM) sector estimated to be worth €700M p.a. in Europe by 2008.  The work will focus on Nylon and CBT (a thermoplastic polyester material). This technology will impact on the 1,100 moulders in Europe.

Our project will develop a core process technology to significantly add to the competitiveness of the SME community by providing them with increased knowledge enabling them to supply competitively on a global basis. The technology we seek to develop will use innovative dielectric sensors to monitor and control the reaction kinetics of the polymerisation process to reduce the in mould cure cycle from 3 to 4 minutes to 45 seconds. This will be achieved by the development of innovative and novel control systems, through increased scientific understanding, enabling the controlled advancement of the polymerisation process and hence the viscosity of the polymer within the extruder/mixer, such that once injected, a mould residence time of only 45 seconds is required to complete the polymerisation process and de-mould the finished part. This technology will enable; 

• Significant reductions in cycle time through mould residence times of 45 seconds instead of 3 minutes
• Three fold greater machine output
• The control and reduction of polymer viscosity (over traditional manufacturing methods) enabling 50% lower machine clamp pressures through the reduced forces involved
• Significantly lower capital investment (40%) through the use of smaller machines
• The manufacture of 50% larger parts for the same machine size
• Reduced energy usage in compliance with the proposed directive on ‘Energy, End-use Efficiency and Energy Services (COM (2003) 739 Final), equivalent to 4m tonnes of energy per annum .
• The placement of preform’s within the mould tool, due to the low-pressure of injection, which can be accurately tailored to achieve the desired engineering properties saving on material scrap of 8%

The market size for RIM is estimated to be €700M p.a. in Europe in 2008. The rest of the world is estimated to be €1300M making a total world market of €2Bn.