FOAM – Software Simulates Foam Manufacturing Process

Digital Twin for Foaming Processes

Due to their low density, foams are attractive for a wide variety of applications. They are used as shock absorbers (crash absorption) or for sound and heat insulation and can be found as seat structures in all kinds of vehicles (wheelchairs, car seats, aircraft seats).

Our software solution FOAM simulates the expansion process of foams in arbitrary geometries and offers the possibility to calculate in advance the foam formation process as well as the resulting foam density in closed shapes. To estimate the necessary parameters for the foam model, targeted expansion tests in cylindrical containers with integrated temperature measurement are sufficient. On this basis, the model parameters are determined automatically and used directly to simulate complex foam filling processes.

Our software FOAM:

  • includes a user-friendly graphical interface.
  • offers an integrated pre-processing tool for CAD-3D data.
  • allows interactive post-processing.
  • uses multicore computer technology and runs on Windows and Linux operating systems.
  • includes automated parameter identification of rheological information from foaming experiments.

 

We offer:

FOAM Simulates Industrial Foaming Processes

The RIM (Reaction Injection Molding) process is often used to produce foamed lightweight structures. Due to their low density, foams are ideal thermal or acoustic insulating materials and are – especially when textile reinforced – are a good substitute for heavy structural or mechanical systems. 

Our FOAM software simulates the RIM infiltration process of foam as well as its expansion through textile reinforcement structures (so-called structural RIM or S-RIM). FOAM is an excellent simulation tool for designing and optimizing chemical foamed foam components and parts. FOAM can also be used to simulate and optimize the manufacturing process of physically foamed materials.

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Simulation des Ausschäumens einer Kühl-Gefrierkombination mit Polyurethan-Schaum

Simulation with FOAM can predict even complicated mold filling requirements such as:

  • Venting points
  • position of the inlet, path movement of the injectors
  • the amount of material required to fill the mold cavity
  • the need to avoid entrapment of gas in the mold

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Simulation of the Foaming of a Cooling Box With Polyurethane Foam

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Simulation of a Continuous Foaming Process of Sandwich Panels

Application Examples

 

Simulation of PU Foam Expansion in Car Seat Manufacturing

Joint project in cooperation with Fehrer Automotive and Audi in which our software FOAM is used and further developed.

 

 

Research Project Technical Textiles

RIM Processes of Polyurethane Foams

In the project FoamInTextil we simulate the foam filling process of Polyurethane foams.

 

Research Project

Complex Dynamics of Expanding PU Foams

Together with our partners at TU Chemnitz we developed a model to predict the complex dynamics of expanding PU foams.