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A new class of nylon-based particle foam for a range of automotive applications has been introduced by BASF. Based on a combination of nylon 6 grades and developed for structural applications, Ultramid Expand comes with a combination of high-temperature and thermal-deformation resistance as well as excellent mechanical properties.

This particle foam consists of prefoamed particles with a defined particle size and density, which can be welded into a 3D component without generating foam waste in molding machines. The component is said to have isotropic properties (the same mechanical properties in all directions), and a chemical reaction does not take place in the foam. It boasts excellent chemical resistance (for example, in contact with fuels, oils and lubricants). Also, its closed cell foam structure is said to offer exceptional compressive strength, a requirement for the use in crash-relevant components that are exposed to high mechanical demands.

Ultramid Expand can be processed with standard EPP vapor-molding machines and is compatible with various thermal welding processes. The material can be used in various automotive components, including occupant and battery protection, structural inserts and battery cell holders. The foam is said to be easy to overmold with compatible materials to create hybrid components that are recyclable while providing a monomaterial solution.