Steam-free particle foam processing

What do technologies for processing and "in-situ" functionalization of particle foams and start-ups have to do with each other? A lot, because as can be read in the latest issue of the trade journal "Kunststoffe", this was one of the insider tips of the last K trade fair in Düsseldorf. For much attention in the plastics scene provides just the young Nuremberg company FOX Velution by its completely steam-free process chain for particle foams.

"Intergalactic Magneto Foam Card": Tool case-produced demonstrator with gently foamed-in functionality (decorative surfaces, foiling, magnetic function and QI charging unit). (Photo credit: HOFMANN Innovation Group/B. Girg) Traditionally, expanding materials such as EPS (Styropor® or Airpop®) must first be elaborately pre-foamed by means of steam before the foam beads - as with expanded polypropylene (EPP) or E-TPU (Infinergy®) - are welded into molded parts in a likewise steam-based process step. The two founders Miriam Lucht and Jörg Vetter have turned this completely on its head: Thanks to their technologies, it is now possible to perform pre-foaming dry and energy-efficiently in just a few seconds using infrared radiation. Mold foaming takes place in generatively manufactured, highly dynamic variothermal molds, which also enables integrated functionalization, which was impressively demonstrated using demonstrators at the K trade show.

Currently, FOX Velution is purposefully driving industrialization in the direction of complex applications and automated manufacturing in a network with five partners. In the processing technology center in Lichtenfels, the entire value chain - from toolmaking (Hofmann Innovation Group, Lichtenfels) to metering (Schenck Process Europe, Darmstadt) and blasting technology (Krelus, Oberendfelden/Switzerland) to mechanical engineering (Fill, Gurten/Austria) - is covered. The area of applied research and development is supported by Neue Materialien Bayreuth GmbH.

This shows that good networks and partnerships can offer great added value and that the full potential of new ideas can be raised in such collaborative constellations. The New Materials Cluster also had a small part in the successful development of FOX Velution. From the very first moment, it was a competent thematic contact and stood by with advice and support and, in particular, with information and contact referrals. The cluster has thus supported the two founders since their step into self-employment.

For more information and contact details, please visit www.fox-velution.de !