New - low volume PU foam parts

Rojac Urethane Technologies a division of Rojac Tooling Technologies now offer low volume manufacture of PU foam parts.
Our facility and capabilities include;

• Two high pressure PU foam machines, one closed loop PC controlled suitable for dual hardness foam.
  
• Double station pneumatic clamping rig with airbags, currently building a 4 double station pneumatic rig turntable with the possibility of 5 axis robotic pouring.
  
• PU foam parts manufactured as follows;
  
  High Resilience Flexible Foams.
  
  Primarily used for seating applications in the automotive industry. All formulations are based on M.D.I chemistry; the resulting foams comply with the requirements of Ford WSK-M2D416-A standard. Dual Hardness foam components may be produced as required. Typical examples include front and rear cushion and seat backs.
  
  Foam in Fabric High Resilience Flexible Foams.
  
  A flexible foam as described above but poured directly into a preformed cover to produce a finished cushion that requires no further covering. Applications are found in automotive head restraints, arm rests and rear seat side bolsters.
  
  Combustion Modified High Resilience Flexible Foams.
  
  Used for seating applications in high quality domestic and office furniture, in addition to public transport vehicle seating. All formulations based on M.D.I chemistry; the resulting foams comply with the flammability requirements of the ‘Crib 5’ test. Single components with weights up to 8.0 Kg may be produced in a range of hardness and densities.
  
  Semi Rigid Flexible Foams.
  
  A relatively firm flexible foam primarily used for interior trim applications in the automotive, transport and furniture industries. Typical examples include console pads etc. Components in a range of hardness’s and densities may be produced to suit the application.
  
  Integral Skin Foams.
  
  Self-finished moulded foam primarily used for trim applications in transport, appliance, equipment and furnishings industries where a hard wearing and impervious sealed surface condition is required. Typical examples include armrests for office furniture, automotive head restraints, component handles etc.
  
  High Density Integral Skin Foams.
  
  A highly durable self-finished moulded foam used for arduous trim applications. Typical examples include high quality floor mats and other trim and liner components for aerospace, marine and industrial equipment applications.
  
  Rigid Foams (Unfilled).
  
  A solid polyurethane foam used in a diversity of applications where light weight solids with good thermal insulation and impact energy absorption properties are required. These can be produced in a wide range of material densities ranging from less than 40KgM-3 to over 500KgM-3. Typical examples include thermal insulation panels for freezers, pipeline insulation and support systems, automotive filler pads, buoyancy fillings and equipment cases etc.
  
  Structural Rigid Foams.
  
  A rigid polyurethane foam reinforced with glass fibre strands to produce a load bearing moulded material. These can also be produced in a range of hardness’s and densities. Typical examples include automotive seat back trim panels, parcel shelves and equipment covers etc.Urethane Cast Elastomers.
  A mouldable elastic polymer used to produce a synthetic rubber type material. Elastomers are widely used in a variety of engineering and construction industries to produce products with good abrasion resistance and vibration damping properties. Typical examples include tires, gaskets, seals and equipment mountings. Additional applications include many components that might alternately be produced by injection moulding such as gear knobs and component handles, etc.
  
  Please contact us enquiries@rojac.com for further information.

E-business helps Rojac onto the Olympic podium

Rojac Tooling Technologies was founded in 1969 and established itself as a market leader in the manufacture of mould tooling, jigs and fixtures, master models, patterns and prototypes.

Much of its core business was within the automotive and aerospace industries with clients including Airbus, British Aerospace, BMW and Rolls Royce as well as Formula One motor racing teams. But the West Midlands company has diversified over the years in order to reach new markets and has embraced new technology too.

This has not only helped Rojac to win new business, it has also improved efficiency and the project management process for all clients. It was this commitment to the use of IT that helped the firm land gold at the last Olympics and should provide inspiration to other local businesses to make full use of e-business.

When it was announced in July 2005 that London would be hosting the 2012 Olympics it sparked scenes of celebration across the country. And since then, businesses all over the UK have been told that there is the potential to win contracts in avast array of areas associated with the sporting showpiece. But many think an Olympic contract, in reality, is beyond their reach and that it will just be large corporations in the capital that win business ahead of the event. Rojac, however, is living proof that Olympic success is achievable for companies outside London as it played a major part in the opening ceremony at Athens 2004. The Olympics & E-BusinessIn August 2003, Rojac received an enquiry via its website that would have a major positive impact on business and raise its profile on a worldwide scale.

“From day one, e-business played a big part in us landing the Olympic contract,” said Duncan Blakemore, managing director of Rojac ToolingTechnologies. “The company that was organising the opening ceremony at Athens 2004 found us through an internet search engine and logged an enquiry. “I am not totally sure what they searched for but it was associatedwith five-axis model making which isa very specialist machine which very few firms have the expertise to use. ”The enquiry basically asked Rojac if itwas capable of helping to create giant statues of Greek Gods to be used during the opening ceremony atAthens 2004. The company accepted the challenge and, once fully briefed, set about designing the statues with CAD. “IT played a part in us landing the contract through the web, but then it was also crucial at every step of managing the project and creating the four statues,” said Duncan.

The first stage was to deliver a prototype of the largest statue. The final version would be 15 metres high but the prototype was just six feet tallbut proved that Rojac had the know-how to deliver.

Because of the logistics of the project, the web-based project collaboration tool OPMcreator http://www.opmcreator.com/ proved a crucial device in the smooth running of the contract.

The client was very often in Athens, but the ability to check progress and liaise with engineers online meant the need for meetings and travel was cut to a minimum.

When it came to the manufacturing stage, it was like a military operation. The largest of the four statues was made out of oasis/foam blocks in five three-metre sections at Rojac’s headquarters in Wednesbury. Then each section was CNC machined to create five giant jigsaw
pieces. The client could watch this process live via a web-cam before the pieces were assembled before being shipped over to Greece for the ceremony.

And the opening event of the games proved to be a proud day for West Midlands manufacturing.
The 15-metre statue stood loud and proud above everything in the water-filled Olympic Stadium before it was exploded into several pieces on which scenes from past games were beamed. In a Russian doll effect, the next statue was revealed by the explosion of the previous one. It was a dramatic start to the Olympics and one of the most exciting moments in Rojac’s history. Duncan added: "It was a fantastic moment for everyone involved in the project. "And it proves that if a company from Wednesbury can land a deal at the Olympics in Athens, there must be hundreds of opportunities for firms in the West Midlands when it comes to London.
"But we couldn’t have done it without our commitment to IT. It helped us win the contract in the first place and then played a major role in the design and management of the project."

Rojac worked on this project as asupplier to Stage One CreativeServices who in turn were commissioned by Jack Morton Public Events.