FOAM – Software Simulates Foam Manufacturing Process

We Offer:

• Foaming of various foams (polyurethane-PU, flexible foam, rigid foam)
• Simulation-based design of foam molds (placement or course of injection nozzles, position of venting, angle of inclination)
• Process design of foaming processes for insulation components, sandwich panels, seats, etc.
• Process design of textile-reinforced PU foam lightweight structures
• Product design of foam components

Examples of Foam Simulation With Videos of the Simulations

• Simulation of Foaming a Fridge-Freezer Combination With Polyurethane Foam
• Simulation of the Foaming of Battery Modules for Thermal Insulation
• Simulation of a Continuous Foaming Process for Sandwich Panels

The highest possible thermal insulation of cooling units is achieved by filling all cavities of the cooling unit with PU foam as far as possible. Through simulation-based optimization of the foam supply as well as the positioning of vent valves, we can determine both the filling process and an almost homogeneous foam density distribution based on CAD data completely digitally with FOAM. 

Additional insulation elements such as vacuum insulation panels are also taken into account in the design calculation;

Cells in a battery module must be thermally insulated from each other (to protect against rapid thermal runaway - overheating of the cell due to a self-reinforcing heat-producing process) and mechanically fixed. Cylindrical cells are often arranged next to each other and the spaces between them are filled with foam.

With our FOAM software, we can simulate the spread and expansion of the foam and use the results to determine in advance whether all areas that need to be filled are reached or whether the foam distribution is homogeneous.

We can also calculate and optimize the simulation of continuous foaming processes with FOAM. For example, in the production of sandwich panels for the roof or wall, PIR or PU foams are applied between the two outer sheets in a continuous manufacturing process.

The calculations with FOAM make it possible to simulate the production process for various sheet metal profiles and foams and thus set the optimum filling behavior and the desired density profile;