Engineering Passion

Foam molds for perfect parts

The right mold
for every application
Foam molds
Facts and gures 2
Facts and gures regarding our foam molds
Consumer goods Consumer goods
Our foam molds can also be put to a wide variety of uses in the construction,
electrical/electronics and white goods industries.
Automotive Automotive Automotive
Consumer goods
Applications
3
Foam molds for perfect parts
The 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 molds
Molds 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 quality
The 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
capability
CCM 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
77
CCM mold in
mold carrier
Mold carrier with mold for door armrest,
front foaming process
Molds for exible foam systems
High output and premium part quality
Foam molds
Molds for exible foam systems 8
9
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 applications
Flexible foams are produced to com-
ply with customer specifications, for
example, the density can vary between
35 - 60 kg/m. 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 dcor
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 specically adapted to the exible 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
Metal seal edges, manually finished/bedded in, milled or eroded
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 molds
Molds for rigid foam systems 10
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 quality
Rigid 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 systems
Consistently high product quality
Your benefits:
Outstanding thermal
insulating properties
High stability
Good flow behavior
High design variability
These molds are specically adapted to the rigid 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
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
All molds with process-specific heating
a) With inserted heat-transfer lines
b) With cast heat-transfer lines
c) With deep-drilled holes
Metal seal edges, manually finished/bedded in, milled or eroded
Plastic seal edges stamped or coated, with specially filled polymer resins
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
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
11
Foam mold for A pillar trim.
Rigid foam back-formed onto film
inserts.
11
12
Foam molds
Molds for semi-rigid foam
Molds for semi-rigid foam
Low cost and energy efcient
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
13 13
Foam mold for instrument panel made of cast aluminum
with face-cast synthetic resin surface
13
These molds are specically adapted to the semi-rigid 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
c) Milled from cast aluminum or aluminum block, inner surface polished
All molds with process-specific heating
a) With inserted heat-transfer lines
b) With cast heat-transfer lines
c) With deep-drilled holes
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
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
With several vacuum circuits for perfect positioning of molded skins
Molds engineered for use with a KraussMaffei mold carrier or self-contained, depending on target production volumes
Foam molds
Long 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
15
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.
15
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 exible integral foam
Tough skin and soft core
Foam molds
Molds for exible integral foam 16
Cable sheathing
Cable 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 wheels
Steering 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 encapsulation
In 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.
17
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 specically adapted to the foaming 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
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
All molds with process-specific heating
a) With inserted heat-transfer lines
b) With cast heat-transfer lines
c) With deep-drilled holes
Metal seal edges, manually finished/bedded in, milled or eroded
Plastic seal edges stamped or coated, with specially filled polymer resins
Optimized demolding concepts for damage-free demolding
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
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
Optimal molds for
premium quality refrigerator doors and cabinets
18
Foam molds
Molds for refrigerator doors and cabinets
19
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
20
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 molds
Special molds
Special molds
From 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
21
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 xtures are specially adapted to process requirements
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
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
All molds with process-specific heating
a) With inserted heat-transfer lines
b) With cast heat-transfer lines
c) With deep-drilled holes
Metal seal edges, manually finished/bedded in, milled or eroded
Plastic seal edges stamped or coated, with specially filled polymer resins
Optimized demolding concepts for damage-free demolding
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
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
22
Foam molds
Further information
Further information
which 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.
23
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.
KraussMaffei
A 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 world
With 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 service
Our 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.com
KraussMaffei Group
Comprehensive expertise
Unique selling proposition Technology
3
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
www.kraussmaffei.com 0
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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 parts
The right mold for every application