Abstract: A composite article is formed with a reaction-injection mold (RIM) foam layer between a substrate and a flexible skin in a RIM tool having at least one inflatable seal defining an edge of the foam layer. The RIM tool is clamped in a fully closed position. A reactive mixture is injected into a space between the substrate and skin with the inflatable seal being deflated. The inflatable seal is inflated to close off the edge when the reactive mixture approaches the edge. Inflation of the inflatable seal and clamping at the fully closed position are maintained for a gel time of the reactive mixture. After the gel time, the inflatable seal is deflated to vent at least a portion of gas produced by the reaction while maintaining the clamping at the fully closed position for a curing time of the reactive mixture.

Abstract: A composite article is formed with a reaction-injection mold (RIM) foam layer between a substrate and a flexible skin in a RIM tool having at least one inflatable seal defining an edge of the foam layer. The RIM tool is clamped in a fully closed position. A reactive mixture is injected into a space between the substrate and skin with the inflatable seal being deflated. The inflatable seal is inflated to close off the edge when the reactive mixture approaches the edge. Inflation of the inflatable seal and clamping at the fully closed position are maintained for a gel time of the reactive mixture. After the gel time, the inflatable seal is deflated to vent at least a portion of gas produced by the reaction while maintaining the clamping at the fully closed position for a curing time of the reactive mixture.