MOLD FOAMING. DEVELOPMENT OF NEW PROJECT. AUSTRIA 2023

We are using foam today in very many applications. We are practically surrounded by products made of foam. Foam comes with shape, comfort, protection. The desired shapes can be obtained by foam cutting: vertical, horizontal, CNC contour cutting, profilling. The results of these cutting processes are the complex 2-dimensional shapes or simple geometrical 3-dimensionl shapes.

When complex 3-dimensional shapes are needed, the cutting processes are not enough and the process of foam injection is used instead. The complex 3-dimensional shapes are usually used for parts with a functional role, used in automotive, in sport or recreation and thus a high degree of final shape quality and comfort are required.

In this particular project, we were asked to produce a product that is used for recreation. The foam injection process consists of mixing two chemical components together, giving a chemical reaction after dispensing into a mold. The material increases in size until the mold vacuum is completed. When the foam has hardened, the part is separated from the mold and the process is repeated.

The key points of the injection were the mold design, material control, deburring for the perfect shape and finishing the products. The mold was made available by the client and deburring was needed after the injection. The design and execution of the molds determine the degree of perfection of the shape. The better designed and executed, the smaller the burr after the injection.

The functionality of these injected forms claims a high degree of comfort. To obtain the desired comfort, material control is essential. In choosing the raw materials and the optimal injection process, we aim to ensure the homogeneity of the final shape, the stability of the final shape, as well as the repeatability of the process.