{"id":12455,"date":"2026-05-11T14:10:25","date_gmt":"2026-05-11T12:10:25","guid":{"rendered":"https:\/\/ikv-aachen.de\/rp\/foam2cycle-2ktsg\/"},"modified":"2026-05-19T14:19:23","modified_gmt":"2026-05-19T12:19:23","slug":"foam2cycle-2ktsg","status":"publish","type":"cpt_ikv_rp","link":"https:\/\/ikv-aachen.de\/en\/rp\/foam2cycle-2ktsg\/","title":{"rendered":"Foam2Cycle &#8211; 2KTSG"},"content":{"rendered":"<style type=\"text\/css\">\n    #single-header-block_662488fa09ba8edf02b6a424d0b0a5a8 .swiperThumbsNavi .swiper-slide {\n        opacity: 0.4;\n    }\n\n    #single-header-block_662488fa09ba8edf02b6a424d0b0a5a8 .swiperThumbsNavi .swiper-slide-thumb-active {\n        opacity: 1;\n    }\n<\/style>\n    <section id=\"single-header-block_662488fa09ba8edf02b6a424d0b0a5a8\" class=\"block-single-header theGridWrapper \">\n        <div class=\"theGrid12\">\n            <div class=\" col-start-2 col-span-10 md:col-start-3  md:col-span-8\">\n                <h2 class=\"font-serif font-semibold text-blue text-sm w-4\/5\">\n                    Thermoplastic foam injection moulding for recyclable 2K soft-touch visible parts                <\/h2>\n                                    <div class=\"mt-base text-blue text-sm font border-l-8  border-blue pl-base my-12 leading-normal \">\n                        Soft-touch components have become established in numerous applications and are now indispensable in areas such as automotive interiors and sports equipment. However, these components typically comprise multiple materials that are inseparably bonded and thus non-recyclable. In particular, the automotive sector faces growing scrutiny due to the European Commission&#8217;s efforts to regulate end-of-life vehicles (ELV directive).                    <\/div>\n                                            <\/div>\n        <\/div>\n    <\/section>\n\n\n\n<p class=\"wp-block-paragraph\">Consequently, the Foam2Cycle project, aims to develop an alternative manufacturing technology. This approach will enable compliance with forthcoming legislative requirements on recyclate content, even for soft-touch and visible components, while facilitating more sustainable products. Central to this endeavour is the integrated development of both material and process technology. In place of conventional soft-touch materials such as PUR and PVC, thermoplastic elastomers will be employed for the soft component, offering material recyclability in contrast to PUR. Polypropylene will serve as the carrier material, yielding a quasi-monomaterial composite.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The material is to be processed in a two-component foam injection\u2011moulding process to produce the soft\u2011touch component. The process variant developed at IKV uses chemical blowing agents for foaming. The injection mould used is designed as a breathing mould, i.e. unlike in conventional thermoplastic foam injection moulding, the cavity volume varies over the course of the cycle (Fig.\u00a01). Following complete cavity filling, a brief holding pressure phase is applied to ensure precise, defect-free replication of the cavity surface. The cavity volume is then increased, prompting the internal material to foam. The degree of foaming can be precisely controlled via the mould opening stroke and determines the resulting foam haptics.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The low density and recyclability of the composite result in a significantly improved CO2 footprint over the entire service life of the component. By relying on established technologies and materials, the cost\u2011effective process can be transferred directly into industrial practice.<\/p>\n\n\n<figure class=\" relative flex flex-col gap-2xs mb-xs md:mb-l xl:mb-xl\"><img decoding=\"async\"  class=\" w-full  \"  src=\"https:\/\/ikv-aachen.de\/wp-content\/uploads\/2026\/04\/ZIM_KK5158711.jpg\" srcset=\"https:\/\/ikv-aachen.de\/wp-content\/uploads\/2026\/04\/ZIM_KK5158711-748x499.jpg 748w, https:\/\/ikv-aachen.de\/wp-content\/uploads\/2026\/04\/ZIM_KK5158711-1536x1024.jpg 1536w, https:\/\/ikv-aachen.de\/wp-content\/uploads\/2026\/04\/ZIM_KK5158711-768x512.jpg 768w\" sizes=\"auto, (max-width: 1536px) 100vw, 1536px\" width=\"1536\" height=\"1024\" alt=\"ZIM_KK5158711\" loading=\"lazy\" \/><span class=\" text-copyright order-3 justify-end text-right w-full  w-full \">&copy; IKV<\/span><figcaption class=\" w-full  text-figcaption justify-end text-right \">Fig. 1: In contrast to classic foam injection moulding (left), the breathing injection mould (right) changes the cavity volume over the cycle. Among other things, this improves the surface quality, eliminating the need for laminating surface layers that prevent recycling.<\/figcaption><\/figure>\n\n\n<details class=\"wp-block-details is-layout-flow wp-block-details-is-layout-flow\"><summary>Project data and funding<\/summary>\n<p class=\"wp-block-paragraph\">We would like to thank the BMWE for funding the project as part of the Central Innovation Program for SMEs (ZIM, funding code KK5158711) and the project partners for their cooperation.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Project duration: 01.06.2025 &#8211; 31.05.2027<\/p>\n\n\n<section id=\"logo-bar-block_6bfe80e6db38a2f3fb97fcf2f3fb7ecd\" class=\"block-logo-bar py-2xl  clear-both\">\n    <div class=\"theGridWrapper overflow-hidden  \">\n        <div class=\"grid grid-cols-[repeat(auto-fill,minmax(140px,1fr))] gap-base\">\n                            <figure class=\" relative h-full  \"><img decoding=\"async\" fetchpriority=\"low\"  class=\" object-contain w-full h-full mb-base  \"  src=\"https:\/\/ikv-aachen.de\/wp-content\/uploads\/2024\/10\/BMWE-Logo.png\" srcset=\"https:\/\/ikv-aachen.de\/wp-content\/uploads\/2024\/10\/BMWE-Logo.png 500w, https:\/\/ikv-aachen.de\/wp-content\/uploads\/2024\/10\/BMWE-Logo-335x335.png 335w\" sizes=\"auto, (max-width: 748px) 100vw, 748px\" width=\"500\" height=\"500\" alt=\"BMWE-Logo\" loading=\"lazy\" \/><\/figure>                                <\/div>\n    <\/div>\n<\/section>\n<\/details>\n","protected":false},"excerpt":{"rendered":"<p>Soft-touch components are established in many areas of application and have become an integral part of car interiors and sports equipment, for example. However, such parts consist of several components that are inseparably connected and cannot be recycled. In the automotive industry in particular, the European Commission&#8217;s efforts to regulate the handling of end-of-life vehicles are increasing the discussion about soft-touch components.  <\/p>\n","protected":false},"featured_media":12411,"parent":0,"template":"","tags":[1039,879,1541,921,1540,956,874,1018,883],"research_fields":[813],"class_list":["post-12455","cpt_ikv_rp","type-cpt_ikv_rp","status-publish","has-post-thumbnail","hentry","tag-automobiles","tag-circular-economy","tag-end-of-life-vehihcles","tag-injection-moulding","tag-polypropylene","tag-pu","tag-recycling-en","tag-thermoplastic-elastomers","tag-thermoplastic-foam-injection-moulding","research_fields-injection-moulding"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v28.3 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Foam2Cycle - 2KTSG | IKV-Aachen<\/title>\n<meta name=\"description\" content=\"Soft-touch components are established in many areas of application and have become an integral part of car interiors and sports equipment, for example. 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