A truck storage tray, produced from polypropylene (PP) by KraussMaffei using MuCell foaming technology. The foam reduces the density of the part, allowing it to become thicker and stiffer without adding weight. Foaming usually leaves surface marks as a result of the flow of the gas during moulding. It is most visible in black parts. The polymer is modified with additives to reduce the effect and surface texture added to eliminate the visual impact altogether. In this case, a textured in-mould label (IML) has been added to the centre (silver), completely concealing the black plastic beneath.
Samples of a unique foamed polylactic acid (PLA) produced by Hemcell. The PLA is prepared with CO2, so that when moulded, the CO2 causes the plastic to foam and fill the cavity. This saves material, reduces weight, and offers some moulding opportunities due to the unique behaviour of foamed plastic.
Expanded foam packaging produced with Kaneka polyhydroxyalkanoates (PHA) bio-based and biodegradable polyester. The packaging is recyclable and compostable, providing an alternative to fossil-based expanded polypropylene (EPP) and expanded polystyrene (EPS).
A Decathlon trainer with thermoplastic polyurethane (TPU) foam midsole. The textile upper is placed in the mould along with the durable TPU outer sole, and over-moulded with TPU using Mucell physical foam technology. This creates a lightweight and durable shoe with excellent rebound and recovery.
Circle Supernatural running show with thermoplastic elastomer (TPE-TPA) foam midsole made with Arkema Pebx Rnew, a partially bio-based elastomer. The knitted textile upper is placed in the mould along with the durable TPE outer sole, and over-moulded with TPE using Mucell physical foam technology. This creates a lightweight and durable shoe with excellent rebound and recovery.
Renault interior door panel made with LYB LyondelBasell polypropylene (PP) with a chemical foaming agent added to produce a foamed part. This approach helps to save 15-20% weight. The texture is designed to eliminate the need for a covering, to save cost and ensure the part can be recycled end of life.
Renault interior door panel made with LYB LyondelBasell polypropylene (PP) with a chemical foaming agent added to produce a foamed part. This approach helps to save 15-20% weight. The texture is designed to eliminate the need for a covering, to save cost and ensure the part can be recycled end of life.
An automotive door inner, produced from polypropylene (PP) using MuCell foaming technology. The foam reduces the density of the part, allowing it to become thicker and stiffer without adding weight. Foaming usually leaves surface marks as a result of the flow of the gas during moulding. It is most visible in black parts. The polymer is modified with additives to reduce the effect and surface texture added to eliminate the visual impact altogether. In this way, a monomaterial part is possible, without any coating or covering necessary.
An automotive door inner, produced from polypropylene (PP) using MuCell foaming technology. The foam reduces the density of the part, allowing it to become thicker and stiffer without adding weight. Foaming usually leaves surface marks as a result of the flow of the gas during moulding. It is most visible in black parts. The polymer is modified with additives to reduce the effect and surface texture added to eliminate the visual impact altogether. In this way, a monomaterial part is possible, without any coating or covering necessary.
A Fraunhofer ICT concept for expanded polylactic acid (EPLA) foam safety helmet. EPLA is roughly equivalent to the price of expanded polypropylene (EPP), but more expensive than expanded polystyrene (EPS).
Cross-section through a rotation moulded sample that illustrates an inner layer of foam, which is used to provide added stiffness without a significant increase in weight. Both materials are polyethylene (PE) and produced in the same moulding cycle: the natural (off-white) skin is moulded and once formed the yellow foaming material is added to the mould. The colour has been added to the foamed PE to highlight the separate materials.
Clouds by Ronan and Erwan Bouroullec for Kvadrat. An innovative, interlocking fabric tile concept for the home made with napped wool fabric surrounding a polyethylene (PE) foam core.
Clouds by Ronan and Erwan Bouroullec for Kvadrat. An innovative, interlocking fabric tile concept for the home made with napped wool fabric surrounding a polyethylene (PE) foam core.
VIA57 chair, by Bjarke Ingels and KiBiSi for Fritz Hansen, 2016, consists of a steel frame, overmoulded with polyurethane foam, upholstered with wool fabric. The legs are lacquered oak
Adidas Ultraboost running shoe, 2015, which uses expanded thermoplastic polyurethane (ETPU) in the sole. Originally developed for Puma by BASF, the eTPU sole technology was adopted by Adidas in 2013 and named Boost. The combination of softness and elasticity provide a high level of comfort and bounce. In addition to the ETPU sole, the Ultraboost shoe features a knitted polyester upper and TPU lace cage and moulded heel support.
Expanded thermoplastic polyurethane (ETPU) midsole. ETPU is known for its superior performance in footwear due to its durability and flexibility. Image Covestro.
A sandwich panel consisting of 3D Core PET (a unique, high performance, conformable polyethylene terephthalate foam core material ideally suited to resin infusion) sandwiched between two layers of polymethyl methacrylate (PMMA), acrylic.
Sandwich panels consisting of a foamed polyethylene terephthalate (PET), polyester, core. The skins shown here are glass fibre reinforced epoxy and aluminium sheet.
The Tesla Model 3 features Tabu wood veneer, dyed to look like walnut, laminated onto an injection moulded carrier. The instrument panel (dashboard) consists of an injection moulded structure, soft foam layer and durable surface foil. The materials for this type of dashboard are typically polycarbonate alloy (PC/ABS) carrier, polyurethane resin (PUR) foam, and thermoplastic polyurethane (TPU) foil.
BASF Elastopan polyurethane resin (PUR) moulded directly onto fabric. Applied in footwear and protective clothing, for example, it offer excellent physical properties like flexibility, abrasion and hydrolysis resistance, durability and low density.
BASF Elastopan polyurethane resin (PUR) moulded directly onto fabric. Applied in footwear and protective clothing, for example, it offer excellent physical properties like flexibility, abrasion and hydrolysis resistance, durability and low density.
Cross section through an automotive instrument panel (dashboard) featuring BASF Elastoflex polyurethane resin (PUR) foam. This is a safety critical part of the design, as well as important visual and tactile aspect, sitting in front of the driver. In must be able to tolerate some demanding conditions - temperature extremes, direct sunlight and heat through the windshield - while maintaining its appearance for the life of the vehicle. They are made with various material technologies, such as with unpainted polypropylene (PP), or as is the case with higher spec vehicles like this example, using PUR foam between an injection moulded structural carrier and tactile surface foil. The foam bonds the carrier, which is typically PP or polycarbonate blended with acrylonitrile butadiene styrene (PC/ABS), to the surface foil to create a smooth profile with soft touch feel. Surface foils include thermoplastic olefin (TPO), and slush moulded thermoplastic polyurethane (TPU) or polyvinyl chloride (PVC). Image BASF.
Memory foam (viscoelastic) polyurethane resin (PUR) is common in mattresses, upholstery and backpack padding. It is an open cell flexible foam, 30-100 kg/m3, characterised by slow recovery rate after deformation. This property is also particularly useful in hospital beds, to prevent pressure injuries in patients immobilised for long periods.
Black expanded polystyrene (EPS) insulation is made with added graphite. The advantage of this material, BASF Neopor graphite polystyrene (GPS), is that not only does it slow down heat transfer the same as EPS, but the graphite additive reflects the heat internally. This further increases the insulation efficiency of the material. It contains 10% recycled material.
Expanded polypropylene (EPP) over-moulded with polyurethane resin (PUR). This type of direct coating, using a rubber-like PUR with texture, is used to create tactile surfaces for automotive interiors.
Expanded polypropylene (EPP) moulded into an injection moulded PP shell. The rigid PP outer provides a visual surface that protects the EPP from indentation and provides additional rigidity.
Looking inside a typical sun visor, which contains an injection moulded PC/ABS structure, and the cavity is filled with moulded expanded polypropylene (EPP), which provides a durable and lightweight body.
Cross-section through an insulated pipe, made with extruded and cross-linked high density polyethylene (XLPE) filled with polyurethane resin (PUR) foam.
Cross-section through rotation moulded part made up of polyethylene (PE) skin and PE foam, produced in a single step. This monomaterial solution is the result of triggering the foaming reaction at a high temperature, which occurs after the skin material has already begun to form on the surface of the mould.
Allbirds Plant Pacer trainers. Upper made from Mirum from startup Natural Fiber Welding (plastic-free plant leather made with natural rubber, plant-based oil, natural pigments, and minerals), lining made with 43% eucalyptus-based Tencel Lyocell and 57% recycled polyester (PET), midsole made with sugarcane-based green ethylene vinyl acetate (EVA), and sole in natural rubber. Image Allbirds.
Wellington boot by Stella McCartney for Hunter, 2019, made with Yulex rubber. The sole and upper are moulded and welded to produce a watertight boot. The stretch-sock insert is a closed-cell foam produced with natural rubber, also from Yulex. This material offers an alternative to neoprene, a synthetic rubber typically used in these types of fabrics, like wetsuits. Image Hunter.
Selasti moulded sole made with I'm Green bio-based EVA from Braskem. The ethylene vinyl acetate (EVA) is 45% to 80% bio-based, depending on the grade. It is produced from residues of sugar cane production, based in South America. At the end of its life, it can be recycled. Image Selasti SPA.
Dansko Kane moulded clogs are made with over 50% I'm Green bio-based EVA from Braskem. The ethylene vinyl acetate (EVA) is 45% to 80% bio-based, depending on the grade. It is produced from residues of sugar cane production, based in South America. At the end of its life, it can be recycled.
Birkenstock sandals moulded in ethylene vinyl acetate (EVA) foam. Modelled on the classic cork and leather sandal, this one-piece shoe is lightweight, waterproof and washable.
Puma RS 100, one-piece injection moulded shoe. Two colours of ethylene vinyl acetate (EVA) are moulded, one on top of the other, to produce a seamless slip on shoe.
Utrecht armchair, by Gerrit Thomas Rietveld for Cassina, 1935, consists of a steel frame, polyurethane padding and blanket stitched pigmented leather upholstery.
Bang & Olufsen BEOPLAY HX headphones feature lambskin leather ear cushions, with polyurethane foam padding and a gold-colour anodised aluminium frame, using the dip and dye method.
Fluorescent-dyed polymethyl methacrylate (PMMA), acrylic, over aluminium foam. The laser cut edge of the acrylic appears brighter than the faces, due to a phenomenon known as edge glow, or lit edge. It is caused by lightwaves being refracted internally and transmitted out through the edge, rather than the surface. The effect is enhanced by fluorescent pigment.
Trax airport seating, by Rodney Kinsman for OMK, 1989, features a self-skinning polyurethane resin (PUR) foam upholstery, cast and powder coated aluminium arms and an extruded aluminium beam
Thermoformed acrylic capped acrylonitrile butadiene styrene (ABS-PMMA), over-moulded on the backside with reaction injection moulded (RIM) polyurethane resin (PUR) for added stiffness. The ABS-PMMA provides a smooth, colourful, durable and UV-resistant outer layer
Spot Material is a database of materials for sustainable design, curated by Rob Thompson. Compare properties, carbon and end of life, find better alternatives and discover new material innovations. Browse all materials
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