Molds for polyurethane and composite materials

The NEXUS mold and thermoregulation system offers a new way to approach RIM applications that takes advantage of composite materials, offering better temperature control, higher energy efficiency, and a much lower weight. 

We provide mold tooling for molded polyurethane automotive seating. Each mold is designed, tooled and tested in-house. 

While we work with the most common Interwet-LFI applications (as a structural reinforcement for a thermoformed aesthetic layer), we also specialize in combining this process with in-mold coating to achieve an exceptional aesthetic surface finish that is ready for painting.

To overcome the typical issues associated with HP-RTM, generally related to the process, materials, and eventual presence of fragile inserts, we developed and patented a specialized device for fine-tuning and controlling pressure inside the mold with extreme precision.

We offer state-of-the-art molding solutions with integrated cutting systems, creating a one-step process. This specialized expertise, acquired from molding automotive fuel tanks, has also been successfully applied to other vacuum-formed products, like automotive air ducts made from PE-PP foam materials.

Longstanding partnerships with leading composite part manufacturers have enabled us to build extensive molding experience with a wide range of materials, ranging from SMC/CF-SMC to pre-impregnated (pre-preg) laminates. We are by your side from the prototype phase through to the start of full-scale production and beyond.

Our wet compression molding solutions for impregnating dry fibers, glass, and carbon — even recycled materials — apply process innovations that increase production performance while reducing the environmental footprint impact, with applications ranging from transportation to medical.

Extensive expertise with the glass fiber and carbon fiber preforming process enables us to develop tools for molding complex geometries, using sequential movements to minimize fiber stretching. Our patented Triple-Vacuum Frame (for dry or pre-impregnated materials) greatly improves productivity and reliability through automated stack transfer and advanced material draping systems.

Ideal for low-medium volume production, these molds are largely used for automotive and commercial vehicles to produce interior components like instrument panels, door panel structures, window frames, roofs, capote pump covers, fenders, bumpers, wheel trims, pillars, and spoilers. They are also used to produce home goods like lamps, tables, mobile carts, and drawers.

Our intelligent Mold Automation System (MAS) solution for manufacturing grommets features a fully-sensorized electronically-controlled mold integrated with the dosing unit and mixing head so you can monitor and control the entire process.

Our manual molds and self-actuated customized solutions for water heaters & heat pumps improve the the polyurethane foam’s insulation characteristics while reducing the quantity of PU needed for injection — all without sacrificing quality.