Foam molds for perfect parts The right mold for every ... · PDF file3 Foam molds for perfect parts The right mold for every application From pouring and foam-molding to backfoaming

Engineering Passion

Foam molds for perfect parts The right mold for every application

Foam moldsFacts and figures2

Facts and figures regarding our foam molds

Consumer goodsConsumer goods

Our foam molds can also be put to a wide variety of uses in the construction, electrical/electronics and white goods industries.

Automotive AutomotiveAutomotive

Consumer goods

Applications

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Foam molds for perfect partsThe right mold for every application

From pouring and foam-molding to backfoaming – KraussMaffei makes molds for creating the perfect parts every time. Molds for open or closed pouring are made of steel or aluminum and/or with a polymer surface if required. Our molds are engineered as custom tools for specific applications and ensure process-specific heating. The molds have demolding concepts for damage-free demolding, are fitted with product-specific seal systems and come with wear-resistant surfaces, if required. This means that process, machinery, mold carriers and molds are perfectly integrated.

The various molding processes at a glance– Clear Coat Molding process (CCM)– Processing flexible foam– Processing rigid foam– Processing semi-rigid foam– Manufacturing glassfiber-reinforced parts (LFI-PU)– Manufacturing flexible integral foam– Manufacturing parts for white goods– Producing special molds

Multiple applications Our foam molds are used to make all kinds of products

Office furniture

Jet skis Boat hulls

Car roofs

Instrument panels

Boat hulls

Foam moldsMolds for Clear Coat Molding (CCM)6

Clear Coat Molding (CCM) is an automated process for coating premium quality substrates, e.g. luxury wood veneers, with a transparent two-component PU system. Typical applications are trim parts for vehicle inte-riors, consumer electronics and the furniture industry.

In contrast to other methods of coating such parts, CCM is a one-step process. The substrate item is positioned in the mold. When the mold closes, there is a gap the thickness of the coating layer left free. This gap is flooded with transparent polyurethane in a high-pressure process. The CCM process produces a premium quality coating in a relatively short time.

Molds for Clear Coat Molding (CCM)Premium quality coating in next to no time

Your benefits: – Premium quality coatings in just

one step– Superior part quality thanks to

repeatable processes– High production rates– Seal tightness combined with

venting capability

Precise temperature control and the system's stable, repeatable process ensure that the manufactured parts meet extremely high criteria for visual quality.

Stable and repeatable process for superior part qualityThe production system has a mold car-rier and a mold. The mixing head is mounted on a centrally positioned robot, so that it can dock alternately onto the molds to discharge the CCM material into the cavities. The wait times between shots are relatively short to eliminate the risk of problems with hardened material residues. This configuration also makes it possible to achieve high production rates.

Combining precision seals with venting capabilityCCM molds have to combine a close tolerance seal with venting capability.

The coating needs to compensate for manufacturing tolerances from previous processes. Maximum seal tightness must be guaranteed with minimal flash, which means the substrate to be coated needs to be held firmly in place.

Our CCM molds are perfectly adapted to the requirements of the process

Molds: a) With highly-polished steel surfaces b) With contoured nickel shell as insert

All molds with process-specific heating: a) With inserted heat-transfer lines b) With deep-hole drilling

Metal seal edges, manually finished/bedded in, milled or eroded

With optimized demolding concepts for damage-free demolding

With product-specific seals in the mold to prevent flash or over-foaming

Process-specific brackets or fixtures for holding inserted substrates

Process-specific venting

77CCM mold in mold carrier

Mold carrier with mold for door armrest, front foaming process

Molds for flexible foam systemsHigh output and premium part quality

Foam moldsMolds for flexible foam systems8

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Flexible foam systems (hot and cold foam) are processed on high-pressure metering machines. High-pressure metering means high-pre-cision metering for PU com-ponents, while high mixing quality ensures splash-free pouring into the mold.

Producing flexible foam from PU has two major advantages: one is a very high out-put, the other is excellent quality.

Flexible foam products for transport and furniture applicationsFlexible foams are produced to com-ply with customer specifications, for example, the density can vary between 35 - 60 kg/m³. Ergonomic seat cushions and seat backs can be produced in a single work process by pouring differ-ent density PU foam to create different hardness zones – the resulting products are outstandingly comfortable and dura-ble. Molds are adapted to the special demands of processing flexible foam, with aluminum, special epoxy resin or steel surfaces and with process-specific heating using either cast heat-transfer lines or deep drilled holes. This makes it possible to produce a wide range of seat cushions, armrests and seat backs with varying hardness zones – using the same PU system and one and the same production unit. Upholstery fabric can be inserted in the mold and foam backed, and inserts can be foamed-in.

It is also feasible to foam onto a sub-strate material; the parts can subse-quently be covered with selected décor material.

Your benefits: – High level of productivity– Optimum part quality– Customer-specific solutions– Manually-finished metal seal edges– Molds are adapted to the special

demands of processing flexible foam– Broad range of applications

These molds are specifically adapted to the flexible foam process:

Molds: a) Surfaced with epoxy resin

– Temperature-resistant up to 150 °C – Resin applied in the front-pouring or surface-coating process

b) With aluminum surface – Cast aluminum, inner surface polished – Milled from cast aluminum or aluminum block, inner surface polished – Special aluminum capable of taking a high-gloss polish

c) With steel surface, milled and polished

All molds with process-specific heating a) With inserted heat-transfer lines b) With cast heat-transfer lines c) With deep-drilled holes


Plastic seal edges stamped or coated, with specially filled polymer resins

Product-specific polymer seals in the mold to prevent flash or over-foaming

Process-specific brackets or fixtures for padding aids, inserts or stiffening ele-ments

Process-specific venting to remove gases generated during foaming from the mold safely and without damaging the part

Molds engineered for foaming in open or closed molds

Molds engineered for use with a KraussMaffei mold carrier or self-contained, depending on target production volumes

Foam moldsMolds for rigid foam systems10

PU rigid foams are used in civil engineering, in industrial plants, in plumbing and heat-ing applications, in air condi-tioning and refrigeration and in district heating applications. The foam systems meet the physical criteria for buildings and comply with the legal requirements in different sectors of the construction industry.

Proven high mixing quality for consistent product qualityRigid foam systems have outstanding thermal insulating properties, even with very thin walls. Their bulk density can be set within a wide range. The rigid foam creates a self-adhesive bond with differ-ent outer layers, the composite elements of which are highly stable. The foam's good flow behavior opens up wide design variability, meaning that even complicated cavities can be filled.

Molds for rigid foam systemsConsistently high product quality

Your benefits: – Outstanding thermal

insulating properties– High stability– Good flow behavior– High design variability

These molds are specifically adapted to the rigid foam process:



b) With aluminum surface – Cast aluminum, inner surface polished – Milled from cast aluminum or aluminum block, inner surface polished – Special aluminum capable of taking a high-gloss polish – With etched graining in the aluminum

c) With steel surface, milled and polished – With etched graining in the aluminum

b) With nickel shell as contour insert




Optimized demolding concepts for damage-free demolding

Product-specific seals (polymers) in the mold to prevent flash or over-foaming

Process-specific brackets or fixtures for parts to be encapsulated, inserts or stiff-ening elements

Process-specific venting



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Foam mold for A pillar trim. Rigid foam back-formed onto film inserts.

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12 Foam moldsMolds for semi-rigid foam

Molds for semi-rigid foamLow cost and energy efficient

Semi-rigid polyurethane foam systems are used mainly for backfoaming films, skins or leather.

Your benefits: – Extremely low-cost production– Short demolding times– Resource and energy efficient

The great advantage of semi-rigid foams lies in their cost-efficiency due to short demolding times, low material consump-tion and the ability to reduce material and energy consumption by using “light-weight” foams with low bulk density. Combining PU foams with PVC, ABS or PU films results in good adhesion. In the automotive industry, the use of foam for sound-proofing and to dampen vibrations makes for a more pleasant driving expe-rience.

Foam mold for instrument panel, milled aluminum, polished surface

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Foam mold for instrument panel made of cast aluminum with face-cast synthetic resin surface

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These molds are specifically adapted to the semi-rigid foam process:



b) With aluminum surfacec) Milled from cast aluminum or aluminum block, inner surface polished


With product-specific sealing systems. There are a number of rigid and/or inflatable sealing systems available, combinations are also possible

Process-specific brackets or fixtures for inserts or stiffening elements



With several vacuum circuits for perfect positioning of molded skins


Foam moldsLong Fiber Injection molding (LFI-PU)14

We are your highly competent partner for molds used in manufacturing structural components reinforced with long glass fibers.

In the LFI (Long Fiber Injection) process, endless fiber from a roving is chopped to length in a cutter. A blower then separates the filaments. Immediately behind the cut-ting unit, the fibers are brought together with the PU from the mixing head and wetted with PU. The fiber/PU compound is poured into the open mold, as a sharply

Molds for Long Fiber Injection molding (LFI-PU)Stable and lightweight parts

Your benefits: – Broad range of applications– Extremely strong yet lightweight parts– First-class surfaces with simple pro-

cess combinations (IMP, film inserts)– Moderate mold and machine costs– High design variability

focused spray cone, using a robotic arm. Once mold filling is complete, the mold is closed and the compound cures.

Specific, localized properties Fiber lengths can be varied between 12.5 and 100 mm and fiber content can be varied continuously during pouring from 0 to 50 percent. 50 percent is the limit to ensure good wetting with PU. Today the most commonly used PU systems are either compact or foamed. This means that the property profile of LFI is com-parable with that of SMC.

LFI mold made from aluminum as combination mold for four different parts

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Long fibers, considerable freedom to design part geometries and the versa-tility of PU systems mean that the range of applications is very wide. LFI parts can vary from a small trim part for a car interior to a large structural part with a Class A visible surface.

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The combination of a light, flexible foam core with a tough, compact skin generates characteristic product properties that are useful for three applications in particular.

Molds for flexible integral foamTough skin and soft core

Foam moldsMolds for flexible integral foam16

Cable sheathingCable harnesses fixed into the required shape and direction with polyurethane are far easier to install, maintain and repair. Complete cable sheathing guar-antees reliable protection against mois-ture – even under extreme conditions.

Steering wheelsSteering wheels with an integrated air-bag cover need to possess a textured, non-slip surface structure, have low-temperature, impact strength and meet all safety design specifications. The scope for attractive design solutions is also very wide.

Glass encapsulationIn glass encapsulation, glass panes are inserted in a mold and overmolded with a compact PU system. The PU material not only acts as a seal, but also com-pensates for manufacturing tolerances, which makes the automated assembly of the glass panes easier.

Non-slip materials ensure that steering wheels are very comfortable and extremely safe to use.

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Your benefits: – Decorative surface with pleasant grip– High abrasion resistance– Good mechanical and chemical resis-

tance– Low thermal conductivity– Moisture repellent

Aluminum foam mold for overmolding plugs

Foam mold for steel steering wheel with etched graining

These molds are specifically adapted to the foaming process:










Product-specific polymer seals in the mold, to prevent flash or overfoaming

Process-specific brackets or fixtures for parts to be encapsulated, inserts or stiff-ening elements

Process-specific venting to remove gases generated during foaming from the

mold safely and without damaging the part



Optimal molds for premium quality refrigerator doors and cabinets

18 Foam moldsMolds for refrigerator doors and cabinets

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Accelerated development cycles and tighter deadlines make it essential that plan-ning and designing processes for your PU plant and tooling are efficient and streamlined.

Our considerable expertise in and detailed knowledge of the white goods industry mean that we can ensure all our molds are process-optimized for refrigerators and refrigerator doors. This includes any subsequent assembly processes. Optimized interface lay-outs ensure seamless communication between our molds and fixtures. We use advanced simulation and inno-vative calculation systems to design and plan your plant or molds. We also undertake CNC-supported mold manu-facturing in dedicated manufacturing facilities.

New product designs and materials can often sideline planners and engineers with time-consuming questions and challenges. We believe it is important to harmonize the process, the plant and the tooling at the early stages of the project in order to avoid technical problems and high costs.

Your benefits: – Process-optimized tooling technology– Advanced planning systems– Considerable expertise gained over

many years

Mold for refrigerator cabinets Side-by-side refrigerator cabinet plug

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One such example is the SkinForm pro-cess, a 2C injection molding process in which each component is itself a two-component reaction material. This cat-egory also includes molds for structural or sandwich parts, where a reaction cast-ing resin is key to bonding the different layers. Another special area is Spray-RIM molds where the part is produced by spraying a reaction mix into the mold.

Each of these types of molds is specially adapted to the process. This starts with the choice of material for the mold – KraussMaffei makes molds from plastic, aluminum or steel – and includes the seals and venting system as well as the chosen slides, flaps, removable parts and inserts necessary for demolding the molded part.

Molds can be made of a combination of materials and KraussMaffei can advise on the best combination for a specific application. Decisive factors are the num-ber of parts to be produced, the material being processed and the part geometry. Reaction molding molds can be built for the temperature range from 30 to 150 °C.

Molds must be tight, even at high temper-atures, the slides must move as specified and reliably, and the entire mold technol-ogy must function as specified for the life of the mold.

KraussMaffei can provide pre-engineer-ing support from an early stage of prod-uct design and can follow this up with support as an extended workbench dur-ing the testing phase.

In addition, we have expertise in and machinery for downstream die punching, trimming and routing processes, so that we can advise here too.

Foam moldsSpecial molds

Special moldsFrom ideas for parts to series production

Special molds are needed for particular materials such as elastomer-modified Nylon® or Caprolactam and PU elas-tomers such as Technogel. KraussMaffei has the opti-mal solution for you for these materials too.

Your benefits: – Comprehensive knowledge of special

materials– Specific mold development for specific

tasks– Long-lasting operability– Support throughout the entire process

chain

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Mold for a caprolactam pulley.

Properties:– Polished surface – Temperature 140 °C – Four external slides and a core pull – Caprolactum poured into the closed

mold

All molds and fixtures are specially adapted to process requirements










With product-specific polymer seals in the mold to prevent flash or over-foaming

Process-specific brackets or fixtures for parts to be encapsulated, inserts or stiffening elements




22 Foam moldsFurther information

Further informationwhich might also interest you

Are you looking for the appropriate solution for post-mold processing and your system business? We offer composite fiber solutions for sophisticated lightweight components and PU rigid foam systems for use in the white goods industry and for manufacturing panels and sandwich parts.

The following brochures are available in print or to download:– Fiber composite solutions for sophisti-

cated parts– Innovative and profitable solutions for

white goods and insulation

You can find our brochures and flyers on other topics online at: www.kraussmaffei.com. On request, we would also be happy to send you information and technical data for our products free of charge.

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The KraussMaffei Group has a global presence. Countries with subsidiaries are marked in dark blue. In the white-colored regions, the Group is represented by over 570 sales and service partners.

KraussMaffeiA strong brand in a unique global group

Cross-technology system and process solutions Whether in Injection Molding, Reaction Process Machinery or Automation – the KraussMaffei brand stands for pioneer-ing and cross-technology system and process solutions in plastics processing worldwide. For decades, our expertise, innovative ability and passionate commit-ment to plastics engineering have been your competitive edge. As a cross-indus-try system provider, we offer you modular and standardized systems as well as solutions customized to your needs.

There for you around the worldWith our worldwide sales and service network, we offer our international customers an excellent basis for a successful business relationship. Due to the close proximity to our customers, we are able to answer your individual inquiries very quickly. We work out the best possible technical and economical solution for your product and production requirements together with you. Test our machine technology for your applications and let our experts put together an indi-vidualized service package for you.

Individualized serviceOur employees from customer service, application technology and service help you with your questions and needs on every topic dealing with machines, sys-tems and processes – around the globe, quickly and with a high level of expertise. We have developed an extensive custom-ized service spectrum with our lifecycle design, which accompanies you through-out the entire lifecycle of your machines and systems. Take advantage of the per-sonal interaction and flexibility we offer in our practically oriented seminars. We carry out customer-specific trainings either at your location or at our sales and service locations.

You can find additional information about KraussMaffei at: www.kraussmaffei.comKraussMaffei Group

Comprehensive expertise

Unique selling proposition Technology3

The KraussMaffei Group is the only pro-vider in the world to possess the essen-tial machine technologies for plastics and rubber processing with its KraussMaffei, KraussMaffei Berstorff and Netstal brands: Injection Molding Machinery, Automation, Reaction Process Machinery and Extrusion Technology.

The group is represented internationally with more than 30 subsidiaries and over ten production plants as well as about 570 commercial and service partners. This is what makes us your highly skilled and integrated partner. Use our com-prehensive and unique expertise in the industry.

You can find additional information at: www.kraussmaffeigroup.com

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y.From pouring and foam-molding to backfoaming – KraussMaffei makes molds for creating the perfect parts every time. Molds for open or closed pouring are made of steel or aluminum and/or with a polymer sur-face if required. Our molds are engineered as custom tools for specific applications and ensure process-specific heating. The molds have demolding concepts for non-damaging demolding, are fitted with product-specific seal systems and come with wear-resistant surfaces where necessary. This means that process, machinery, mold carriers and molds are perfectly matched.

Foam molds for perfect partsThe right mold for every application

Documents

Foam molds for perfect parts The right mold for every ... · PDF file3 Foam molds for perfect parts The right mold for every application From pouring and foam-molding to backfoaming