Innovative, release agent-reduced manufacturing concepts for the manual series production of complex foam parts

The production of complex foam parts with a number of inserts posses is very labour-intensive. Furthermore, state of art in the foam part production is the usage of any kind of release agents as demolding aid. Many times the release agent system is based on unhealthy solvents and contains silicon compounds to optimize the separating effect. Due to the high scope of manual activities, there is a direct contact between the operator and hazardous substances. To achieve a reduction of the risk potential in conjunction with an increase of the productivity, three different possibilities are conceivable. Beside an automation of the coating process, also a spraying support for the operator is possible to minimize the usage of release agent by an optimal coating procedure of the moulds. In the wake of this, synergies between the different production concepts of various industrial sectors should be created and adapted to the foaming process by an intelligent system engineering. At least an option should be examined which excludes any kind of release agent out of the foaming process. The refinement of this system should show a completely new way of manufacturing foam parts.