Atomized polyurethane in a process known as spray transfer molding (STM) is an efficient way to create strong, lightweight interior and exterior automotive components in nearly any design or shape.
BASF has the capabilities to bring an idea from concept to production with the right designs to match OEM specifications.
Spray transfer molding is a process where atomized polyurethane particles are sprayed onto a non-woven material with a high-pressure nozzle, then molded into the desired shape, providing a rigid, lightweight design.
“Spray transfer molding typically uses a fabric supported by a core material such as paper, foam, metal or polymer, which is then overlayed with a fiber reinforcement and sprayed with a two-component polyurethane system,” says Michael Barry, Market Segment Manager at BASF. “Next, it’s put into a press that molds it to the final shape as the polyurethane cures, and the result is a component that’s very stiff and light relative to other solutions.” – refer Global – Performance Polymers.
A blank of dry fiber is held by a programmable robot that has an optimized and controlled spray pattern. It is then sprayed using a high-pressure nozzle head atomizing the spray polyurethane, the robot will lay down the impregnated blank into the tool to be fully molded and cured. The process is designed to scale from initial ideation and experiments to actual automotive production components.
Innovative technology that sprays the upper part of the sneaker onto a foot-shaped mold twirled around by a robotic arm. The system eliminates the need to source and stitch together individual pieces of fabric. A sneaker materializes in about three minutes using technology. The LightSpray project started in 2019 when one of the company’s developers spotted student Johannes Voelchert at the Milan Design Show now being used to create complex three-dimensional forms.
Fine-tuning the spray was an arduous process. The upper part of the sneaker is made from synthetic materials known as polymers, which behave differently depending on how they are combined, heated, and sprayed. The team tried hundreds of combinations before finding a formula that was durable but also flexible and comfortable.
To make the shoe, a single mile-long polymer filament is sprayed onto a standard mold. First, it is bonded to a pre-manufactured sole and then the material is layered up until the upper is fully formed. Colors and logos are then laser-printed onto the shoe.
Although invisible, Elastoflex® E semi-rigid foams contribute extensively to the valuable appearance in car interiors, since the foam is behind most skin surfaces and causes a pleasant, soft and elastic touch. Though it needs to fill even smallest gaps between carrier and skin it spreads homogeneously at very robust processing.
Example of the Automotive car part featuring a honeycomb sandwich structure with a class A film (Spray Transfer Molding technology from BASF). It is 30% lighter than the standard roof on the previous model.
Spray Transfer Molding can be used in a variety of applications and industries ranging from automotive to construction to consumer to industrial manufacturing. Some production applications for automotive that include door interiors, arm rests, load floors, sunshades, hatchbacks and package shelves. Refer to North America – Performance Polymers.
