Technical Information
PulPress Technology with ROHACELL®
The mobility sector is increasingly interested in
injection systems, followed by feeding it into a
using composites to reduce vehicle weight and
movable press system that continuously process-
CO2 emissions. Until now, these materials saw use
es the reinforced core at elevated pressure and
mostly in luxury-class vehicles, since established
temperature. The final 3D profile part that emerg-
production methods were costly and complex.
es is fiber reinforced (FRP) and resin impregnated,
with consistent and accurate dimensions. Parts
With Evonik’s “PulPress Technology” combining
can even include integrated inserts.
both pultrusion and press processes, things are
different. Now manufacturers can replace metal
with composites, without paying a high price tag.
Process innovation & production
ROHACELL® polymethacrylimide (PMI) foam is a
lightweight, strong core material used for over 40
years in sandwich structures in many industries,
including automotive, aviation and sports equipment. With a glass transition temperature (Tg) of
180 °C (356 °F), ROHACELL® enables quick resin
curing and is easily thermoformed. These properties make it perfect for PulPress technology.
The PulPress process begins by guiding a ROHACELL® core into fiber reinforcement and resin
Technical & economic advantages
The efficient PulPress process guarantees high
production speed, tight tolerances and excellent
mechanical properties of the finished parts. The
compact production line delivers an output of 30
components per hour when using a conventional
resin system. Output can be increased by using a
fast-curing resin system.
Evonik Resource Efficiency GmbH | February 2017 | Page 1/2
Quick and continuous processing with almost no
could conceivably be applied as a cost-effective
waste during part production means a significant
method for producing carry-over parts. Light-
reduction in the cost of manufacturing, up to 60%
weight sandwich cores are also growing in popu-
compared to classical FRP processes (e.g. RTM).
larity among sports equipment manufacturers.
In the automotive industry, complex profiles can
be used as structural components in the car body
or as add-on parts.
Economic advantages of sandwich components
are notable since the finished weight of fiberreinforced parts are up to 75% less than typical
structural steel parts of like performance.
These low density parts demonstrate excellent
To illustrate performance, a PulPress car bumper
load carrying capacity during buckling and very
demonstrator was tested to the RCAR vehicle
high-energy absorption capacity on impact.
crash standard used in setting German insurance
ratings. Results showed a reduction of intrusion
Large potential for many applications
The PulPress process has potential for many industries, including aircraft construction where it
depth of nearly one-third the part weight, confirming the value this process brings to the next
generation of safe, lighter weight vehicles.
ROHACELL® is a registered trademark of Evonik Industries AG and its subsidiaries
This information and all technical and other advice are based on Evonik’s present knowledge and experience. However, Evonik
assumes no liability for such information or advice, including the extent to which such information or advice may relate to third
party intellectual property rights. Evonik reserves the right to make any changes to information or advice at any time, without prior
or subsequent notice. EVONIK DISCLAIMS ALL REPRESENTATIONS AND WARRANTIES, WHETHER EXPRESS OR IMPLIED, AND SHALL
HAVE NO LIABILITY FOR, MERCHANTABILITY OF THE PRODUCT OR ITS FITNESS FOR A PARTICULAR PURPOSE (EVEN IF EVONIK IS
AWARE OF SUCH PURPOSE), OR OTHERWISE. EVONIK SHALL NOT BE RESPONSIBLE FOR CONSEQUENTIAL, INDIRECT OR INCIDENTAL
DAMAGES (INCLUDING LOSS OF PROFITS) OF ANY KIND. It is the customer’s sole responsibility to arrange for inspection and testing
of all products by qualified experts. Reference to trade names used by other companies is neither a recommendation, nor an endorsement of the corresponding product, and does not imply that similar products could not be used.
Evonik Resource Efficiency GmbH
Darmstadt, Germany
Phone +49 6151 18-1005
www.rohacell.com
Americas
Evonik Foams Inc.
Theodore, Alabama, USA
Phone +1 866 764-6235
Asia/Pacific
Evonik Degussa (China)
Shanghai, China
Phone +86 1391 6212034