DS Smith Brand Logo: Foam Products
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Material Surfacing

Look beyond the beads by adding a texture or surface skin to your product.

New technology allows you to achieve a class ‘A’ surface finish on our EPS and EPP foams.  This gives you more flexibility and allows lightweight, energy absorbing components to be on display with their improved aesthetics.

Surfacing will improve the material properties and enhance visual and tactile appeal by disguising the natural bead effect.

  • Create an ‘A’ surface finish
  • Add strength to your product
  • Add value to your product
  • Reduce costs
  • Remove a secondary operation

Flocking

Create a soft velvet like feel on an expanded foam surface

Flocking consists of electro statically charged finely cut natural or synthetic fibres.

First, applying an adhesive to the part, these electro-statically charged particles are then attracted to the part which sticks to the adhesive. Any excess is collected by vacuum and re-used, creating a very even high quality finish.

Flocking imparts a surface effect unlike the normal substrate surface to which it is applied.

It can create:

  • A soft velvety surface on a hard moulded plastic
  • A non-scarring surface on a metal
  • A highly abrasive surface on a smooth paper
  • A luxurious feel on porous foam
  • A contrasting or complimentary surface, or substrate combinations

We have access to wide range of colours and finishes, please feel free to contact us for further information.

Sintered Bronze

Achieve a class 'A' surface finish that hides the natural bead effect of the material

Look beyond the beads and give your product a quality surface that will improve the material properties and enhance visual and tactile appeal by disguising the natural bead effect.

  • Create an ‘A’ surface finish
  • Add strength to your product
  • Add value to your product
  • Reduce costs
  • Remove a secondary operation

Sintered bronze allows the steam required during the moulding process to pass through it, unlike other surfacing techniques there are no visible vents necessary and the whole surface acts as one big vent. Sintered bronze can completely conform to any 3D shape requirements and with the correct maintenance ensure a capable method of ensuring and A class finish.

Tool Etching

Surface textures can be achieved by laser or acid etching

Etching can be achieved by laser or acid methods which will remove material directly from the tool (Metal off) to give a defined uniform texture across the surface of the moulding. There are limitless variations that can be scribed onto a tool, and through creative design we are able to hide the natural bead effect of EPP and remove the marks left by filler guns, ejector and venting.

Tool Meshing

The mould tool cavity is lined with either a grid or mesh to give the desired effect.

Meshing is the simplest way to add a texture to your part, the cavity inside the tool is lined with either a grid or a mesh and is then fixed in place. This technique is the most cost effective way to improve the surface finish or offer anti squeak solutions, however it must be noted that this only feasible on simple relatively 2D parts with typically low run lengths.

TEPEO®

TEPEO® is a surface film that can be applied to give your product a soft touch, quality finish.

TEPEO® is a cost effective way to achieve a soft touch, quality finish to your product. In partnership with Benecke-Kaliko we at Foam Products have developed a range of films that can be back foamed to any of our expanded Polypropylene materials.

TEPEO® covering are widely used throughout the automotive industry for the following applications:

  • Dashboard instrument panel
  • Centre console
  • Interior door panels
  • Side pillars and floor panels

TEPEO® product benefits

  • Lightweight
  • Wide selection of colours and finishes available
  • Good resistance against ageing when exposed to sunlight and heat
  • 100% recyclable

Armordon®

Armordon® films have a similar structure and strength as carbon fibre but at a fraction of the cost.

Armordon® is a self-reinforcing Polypropylene fabric. When layered and thermoformed it delivers a series of appealing material properties that are hard to beat. Developed and manufactured in the United Kingdom, Armordon® provides excellent strength when resisting impacts even at a low density.

  • 100% recyclable
  • offers significant environmental benefits
  • no glass reinforcement
  • gains in both processing and machining.

With a wide variety of applications including luggage, body armour, automotive components and protective sports gear, Armordon® has the edge over traditional materials used in these sectors.