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.
Relevant materials
Polypropylene (PP), PP, Foam
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Automotive, Foam, In-mould label (IML), Injection moulded, KraussMaffei, Lightweight automotive, Monomaterial, MuCell, Plastic, Polypropylene (PP), Texture
The front grille for the BMW iX is produced in a cleanroom environment, since any dust would be visible through the high-gloss polyurethane (PUR) finish. Produced in an integrated process, the component consists of a functional film that is back-injection moulded with polycarbonate (PC) and then flood-coated with 2-3 mm PUR. Engel developed the production cell.
Relevant materials
Polyurethane resin (PUR), PUR, Coating, One-part, two-part, liquid, powder, over-mould Polycarbonate (PC), PC, Engineering plastic, General purpose
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Automotive, BMW, Electronics product, Engel, In-mould decoration (IMD), In-mould electronics (IME), Injection moulded, Lightweight automotive, Paint, Polycarbonate (PC), Polyurethane resin (PUR), Transparent
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.
Relevant materials
Polypropylene (PP), rPP, Plastic, Recycled Polypropylene (PP), PP, Plastic, General purpose
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Automotive, Foam moulding, Furniture, Injection moulded, Lightweight automotive, Plastic, Polypropylene (PP), Product, Recycled
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.
Relevant materials
Polypropylene (PP), PP, Foam
More
Automotive, Foam, Foam moulding, Injection moulded, Lightweight automotive, Monomaterial, Plastic, Polypropylene (PP), Transport
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.
Relevant materials
Polypropylene (PP), PP, Foam
More
Automotive, Foam, Foam moulding, Injection moulded, Lightweight automotive, Monomaterial, Plastic, Polypropylene (PP), Transport
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