Less is more

Thin-wall foaming makes thinner foam layers possible

With its combination of shapes, surfaces and colors, the interior is a significant part of the overall premium concept of a car. The feel of the car interior also determines the impression and physical well-being of the passengers. The pleasantly soft texture of the surfaces is usually achieved with a layer of PU foam between the carrier and the surface material. Especially in large components, this often means numerous layers of foam. And the components generally become heavier because more relining material has to be used.

Advantages of thin-wall foaming
„The thin-wall foaming method developed by DRÄXLMAIER has enabled components, like instrument panels, to be made with extremely thin-walled foam filling“, explained Dr. Isabella Schmiedel, who is responsible for Technology & Innovations Management and who also co-authored the article. That is mainly due to the fact that with that method – compared to classical back-foaming – minimum foam thicknesses are not needed. And there is no need for waterproofing in the peripheral areas or full surface support of the carrier.

Other areas of application
„The different foam thicknesses also enable individual haptic profiles to be created. For example, flexible upholstery pads can be made in the component surface”, explained Klaus Mussack, interior specialist  at DRÄXLMAIER, other application areas of thin-wall foaming. Because of its advantages, the method is already being used in series in three carlines

Read the whole article about thin-wall foaming that was published in September in the ATZ here.

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