Foam technologies

Foamed materials are increasingly used for transport packaging, heat insulation of buildings and also in the automotive sector. The development of new foamed materials and foam compounds aims to optimize these products, for example in terms of temperature resistance, energy absorption or recyclability.

Foams with tailored properties have attracted increasing attention in the field of material development. Emphasis is placed on the development of foamable polymer compounds in the extrusion process, based on renewable resources and on the targeted use of functional additives, for example to improve the mechanical and thermal properties or to achieve environmentally-friendly fire protection.

For the development of extrusion-foamed semi-finished products, sheets and foils, Fraunhofer ICT has a cutting-edge Schaumtandex laboratory unit, which consists of a twin-screw and a single-screw extruder. With this equipment it is possible to test and specifically enhance new materials and blowing agent formulations in sheets, foils or profiles, with limited resource requirements. With this tandem foam laboratory unit we can offer our partners and customers extensive expertise in material and process technology in the field of extrusion.

The entire process chain of particle foam technology is available at Fraunhofer ICT, for:

• Material development and optimization of the foam structure in the extrusion process
• Development of foamed beads, or expandable granules, by extrusion and subsequent underwater pelletizing
• Investigations into the pre-expansion of granules to form foamed particles in the laboratory pre-foamer
• Investigations into processing in steam chest molding machines (based on steam and radio frequency)
• Autoclave / batch foaming of particle foams
• Characterization of insulation properties or mechanical parameters of the foams in the in-house testing lab

This complete process chain forms the basis for successful cooperation with our partners. New material mixtures can quickly be characterized in terms of their processability and component properties, for example their insulation properties.

In addition to material and process development of particle and extrusion foams, we also offer comprehensive characterization of thermoplastic as well as thermoset foams along the entire process chain from raw material to component. The material testing laboratory at Fraunhofer ICT has the laboratory and pilot facilities necessary to generate material data for the evaluation of raw material development or process influences and material data sheets. Through structural examination and material analysis, we achieve a reliable statement on the quality of the finished component.

• Analysis of the microstructure
• Thermal conductivity
• Mechanical and physical testing, comprehensive standardized testing methods for generating material data sheets or evaluating process influences
• Flammability tests
• Special applications: hydrostatic pressure test
• Rheological testing methods of foam raw material
• Thermal and chemical analysis of foam raw material

Further information:

Material characterization and failure analysis