Yonda chair by Neunzig°design studio for Wilkhahn features oak legs and and injection moulded recycled polypropylene (rPP) top with 20% wood filler.

Cross-section of a foam sandwich injection moulding. The white outer is virgin polypropylene (PP) and the black core is foamed recycled PP (rPP). The layers are formed by first injecting the white (the colour has been used to emphasis the technology in this case) and then injecting the black with chemical foaming agent (CO2). The black rPP forms a bubble inside the white, pushing into onto the surface of the mould. In application, the surface layer would be the same colour as the core to create a high quality visual surface. This example is a cross-section through the LimbicLife ergonomic chair seat. The process and tooling were engineering and optimised by Deckerform.

Cross-section through a concept automotive seat by Johnson Controls and Camisma, manufactured with a combination of thermoforming and injection moulding. Sheets of continuous and unidirectional 12k carbon fibre and in-situ cast PA12 are combined with powder impregnated PA12 nonwoven recycled carbon fibre. They are placed into the mould and thermoformed, prior to back injection moulding of the rib structure using 30% long glass fibre filled PA12. Compared to a steel equivalent this structure saves 50% of the weight.

Concept automotive seat by Johnson Controls and Camisma, manufactured with a combination of thermoforming and injection moulding. Sheets of continuous and unidirectional 12k carbon fibre and in-situ cast PA12 are combined with powder impregnated PA12 nonwoven recycled carbon fibre. They are placed into the mould and thermoformed, prior to back injection moulding of the rib structure using 30% long glass fibre filled PA12. Compared to a steel equivalent this structure saves 50% of the weight.
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