A client from the heavy truck industry contracted Romeo RIM, Inc. to reaction injection mold (RIM) a DCPD air deflector. To begin this process, we first worked closely with our customer on the design of this product. Meeting a ± 3mm tolerance, we then used our 300-ton press to fabricate a 9'x8'x4' part. Once we completed the RIM process, the air deflector was placed on a dual head fixture, where we were able to check all part dimensions before mounting holes were drilled.
The customer wanted their air deflector to be constructed from a lighter material that would reduce the part's weight over previously existing deflector models, while maintaining the unit's superior impact performance. We chose to build the deflector from DCPD, which provided a 30% weight savings over previously used material. DCPD is a unique substance that allows customers to design lightweight and durable large parts.
The air deflector also possessed a unique design, which increased overall aerodynamics to improve fuel economy. In addition, the air deflector contained a "B" side geometry, which endowed the unit with additional strength in specific regions. After this part was manufactured, the deflector was primed and shipped to a final location for assembly and top coat painting. Our services on this project satisfied our client's expectations for quality design and workmanship.