RIM Cart Is on a Roll With In-Mold Decorating

A new method of producing hospital trolleys uses decorative thermoplastic film inserts to eliminate the cost of painting.

A new method of producing hospital trolleys uses decorative thermoplastic film inserts to eliminate the cost of painting. New Aurion Mini trolleys from GMP S.p.A. of Oderzo, Italy, weigh only 37.4 lb—half as much as previous models. This is achieved by molding Baydur 60 PUR integral-skin foam from Bayer MaterialScience (U.S. office in Pittsburgh) with a film insert in the mold. GMP uses a PVC film with a special PMMA acrylic coating to meet the hospital’s hygiene needs.


To produce each trolley side panel, rear panel, and shelf, two thermoformed PVC films are placed in aluminum molds and back-foamed at low pressure with the Baydur 60 PUR integral-skin foam system. The space between the two rigid shells is then filled in the same mold with Baydur 20 PUR foam of 12.5 pcf density. This filling adds stiffness and bonds the two shells without additional adhesive. The trolley base is made from glass-reinforced Baydur foam (with a film insert) to make it strong enough to mount the casters.