The IKV at the K 2025
Sustainable production, recyclate processing and AI methods in the plastics industry
Foam2Cycle
Recyclable soft-touch lightweight components
Why Foam2Cycle?
We encounter soft-touch components everywhere: in vehicle interiors, electronics, sporting goods and household appliances.
The problem is that they usually consist of different, firmly bonded plastics – and are therefore virtually impossible to recycle mechanically.
With Foam2Cycle, IKV presents a new production concept that combines two worlds:
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Soft-touch feel for comfort and design
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Circularity for sustainable products – not only in the automotive industry
The IKV concept
The Foam2Cycle project focuses on an innovative production concept that combines the special requirements of soft-touch components with the principles of a sustainable circular economy. IKV relies on the Design for Recycling approach. Instead of the usual combination of different, non-separable materials, only thermoplastics that are compatible with each other are used for the carrier and soft component. This means that both components can be recycled together without the need for time-consuming separation.
The concept also utilizes the potential of foaming: both the rigid support and the soft surface are foamed.
This not only leads to a considerable reduction in weight, but also to a particularly efficient use of materials. The soft feel and the desired thickness of the component can be individually adjusted – an important aspect when it comes to combining functional requirements and comfort.
For production, IKV uses a process that has proven itself in industrial production: the two-component foam injection molding process. This process has been specifically developed and optimized at the institute so that it is suitable for economical series production. Foam2Cycle demonstrates that sustainability, lightweight construction and industrial efficiency are not mutually exclusive, but can be combined in a holistic solution.
© IKV
© IKV
© IKV
© IKV
© IKV© IKV
The trade fair demonstrator
A modular palm rest with soft-touch haptics for the computer keyboard will be produced live at the IKV stand:
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Lightweight construction due to high degree of foaming (up to 80 % density reduction with TPE)
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Individually adjustable softness and thickness
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Recycling-friendly design – all components are made from recyclable thermoplastics
Materials:
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Carrier: impact-modified polypropylene (PP)
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Soft component: styrene-diene block copolymer (TPE-S)
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Both materials available with 30 % recycled content
| Technological highlights | |
| 2K foam injection molding with chemical blowing agent: fine foam structures, high foaming rates, cost-efficient without additional peripherals | |
| Insulating mold coating: | improved surface quality for PP without complex variothermal tempering |
| Laser-structured tool surface: : various high-quality surface grains for laminating defects in the TPE | |
| Breathing Mould: | enables targeted adjustment of the haptics and different degrees of foaming in the same component |
The research project KK5158711HD4 of the Research Association for Plastics Processing is funded by the Federal Ministry for Economic Affairs and Energy as part of the Central Innovation Program for SMEs on the basis of a decision by the German Bundestag. We would like to thank all our partners and institutions.
Foam2Cycle live at the K 2025:
IKV will be exhibiting a fully automated 2K injection molding machine with a rotary table mold:
Fully digitalized plant technology for AI-supported process setup, control and monitoring
Data integration via the OSPHIM platform: digital shadow of the process, prediction of rejects, data-driven optimization
100% inline quality inspection of surface, feel and dimensional accuracy
Sensors: combined pressure and temperature sensors in both cavities, incident light/transmitted light camera for defect detection
Jan Wolters, M.Sc.
Research assistant
foam injection moulding
Detect before defect
Early detection of roller clogging in extrusion processes
Why Detect before defect?
During flat film extrusion, deposits can form on the chill roll, which can quickly lead to quality losses, rejects and unplanned downtime. With recyclates in particular, the formation of deposits is difficult to predict – the problem often only becomes apparent when it is already too late.
The IKV concept
With Detect4Defect, IKV presents an optical in-line inspection system that continuously monitors the roller surface. Gloss changes caused by incipient deposits are reliably detected and quantified. This allows roller deposits to be localized at an early stage and removed in a targeted manner – without having to interrupt production.
The system is easy to integrate into existing systems and for the first time enables
efficient process monitoring even for small and medium-sized companies. At the same time, it provides valuable data for research in order to better understand the mechanisms of coating formation and to make future processes more robust.
An indication of the high practical relevance of the project: Detect before defect was in the final selection for IGF project of the year in 2025.
We’d like to thank our supporters and partners
Would you like to put the research results into practice? The project is open to other cooperation partners who are interested in transferring the results into practical applications together with IKV and using them for their own purposes. Companies can participate in the research consortium or contribute bilateral questions.
Dr.-Ing. Lukas Seifert
Deputy head of department
extrusion and rubber technology
© IKVDetect before defect live at the K 2025:
IKV will be demonstrating the process live at K 2025: a rotating chill roller with prepared coatings will be monitored with a camera and lighting. Visitors can follow in real time how the system detects deposits, creates a digital image of the roller and analyzes the formation of deposits.
Technological highlights
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Optical camera system with high resolution and line illumination
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Real-time data evaluation and quantification of coating formation
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Easy to retrofit in existing systems
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Potential for coupling with a cleaning system – without stopping production
Dr.-Ing. Lukas Seifert
Deputy head of department
extrusion and rubber technology