Essentially Rubber: Walking on air

Leading-edge designs and applications showing how elastomer materials contribute to all aspects of life and lifestyle in the 21st century:

BASF has extended its Ultrasim R&D simulation portfolio for plastics applications to also cover the manufacture components made of particle foam based on its Infinergy expanded thermoplastic polyurethane (TPU). The material is used as ‘pneumatic filling’ in applications ranging from bicycle tires to shoe soles. During manufacture, the particles are distributed in a mould using compressed air. The new capability, explains simulation engineer Moritz Höfert, helps manufacturers to optimise parameters such as air-flow within the mould, venting, and placement to avoid air pockets. It also simulates how closing the mould changes particle-packing and finally how finished parts perform under load. "For example," added Martin Vallo, senior manager global tech development, “in a shoe midsole, the filling affects the density and stiffness of the sole. Ultrasim simulation can optimise these two parameters - and fully exploit the potential of [the expanded TPU material]."