ORS creates products that can withstand almost anything

With the Opido Reinforcement System (ORS), we reinforce thermoplastics with polyurethane – and obtain components that are light, stiff and impact-resistant at the same time.

Portrait of Espen Johansen, project engineer at Plexx AS.

Espen Johansen
Project Engineer Plexx

A robust, black plastic cover reinforced with a layer of polyurethane on the back via the ORS system.

How does ORS work?

The combination of polyurethane and thermoplastics results in products that are lightweight, dimensionally stable and highly impact-resistant. The polyurethane significantly increases the rigidity of vacuum-formed parts, while also insulating against cold, heat and sound. The end product achieves a rigidity on par with glass-fiber reinforced polyester – without the disadvantages associated with thermosets.

CROSS-SECTION OF AN ORS - CONSTRUCTION

Illustration of how the ORS polyurethane core can be applied in custom thicknesses to the back of a plastic panel.

ORS CAN BE SUPPLIED IN CUSTOM THICKNESSES

How we do it

A lightweight, expanding polyurethane foam is sprayed onto the back of the vacuum-formed part to the desired thickness. The foam hardens, bonds to the thermoplastic, and forms a rigid, insulating core. The method can be combined with a variety of other materials – from metal inserts to composite reinforcements – and is adaptable to both small series and volume production.

"Polyurethane combined with thermoplastics creates light, stable and strong products that can withstand almost anything."

Recyclable

ORS products are not considered hazardous waste. The material complies with current EU directives and can be recycled as secondary raw material – an important plus in the environmental accounts and for products that are to be certified.

Examples of products

ORS is used in everything from bathtubs and ship interiors to bodywork details, industrial components and covers on heavy vehicles and construction machinery. Wherever a combination of low weight, high stiffness and good impact strength is required, ORS is a competitive alternative.

A gray, vacuum-formed industrial cover with light gray ORS reinforcement on the inside for maximum bending rigidity.

THE COMBINATION OF LOW WEIGHT AND HIGH RIGIDITY MAKES ORS WELL SUITABLE FOR THE CONSTRUCTION OF COVERS

The inside of a yellow plastic machine hood with molded metal brackets and threaded inserts in the ORS core.

Close-up of the back of a black body part where the expanding polyurethane foam forms a rigid sandwich structure.

Fasteners can be integrated

Screws, threaded inserts, brackets and other fasteners can be molded directly into the strong and elastic polyurethane core. The result is sandwich constructions with high rigidity and low weight, where assembly and disassembly are made easier throughout the product's lifetime. Hoods and covers for construction machinery are good examples – robust enough for tough use, while being easy to handle in the workshop.

Frequently asked questions

ORS (Oriented Reinforced Structure) are vacuum-formed plastic products reinforced with fiberglass or other composite materials. The result is lighter than steel, but with comparable strength.
ORS provides significantly lower weight, high impact strength, corrosion resistance and design flexibility — while tooling costs are lower than for example steel pressing.
ORS is used in, among other things, transportation, agriculture, construction machinery, medical equipment and cleantech — industries where light weight and high strength are crucial.
Yes, in many cases, ORS can replace steel and aluminum with reduced weight and lower manufacturing costs, without compromising structural integrity.
Absolutely. We assist throughout the entire process — from concept development and 3D design to prototyping, testing and series production.

Are you considering ORS for your product?

We help you from concept to series production – with vacuum forming, ORS reinforcement and integrated fastening solutions.