Asahi Kasei Showcases mPPE Particle Beads Foam at JEC World 2025

JEC World 2025 Asahi Kasei to present easy-to-process particle foam for composite foam core applications

2025-02-13 Source: Asahi Kasei 1 min Reading Time

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Japanese technology company Asahi Kasei will exhibit its mPPE particle beads foam Sunforce at the upcoming JEC World 2025. Its combination of high processability and design flexibility makes it an optimal solution as foam core or sandwich material of composite applications.

Demonstrator of a propeller made of CFRP + Sunforce, finished part(Source: Asahi Kasei) — Demonstrator of a propeller made of CFRP + Sunforce, finished part
(Source: Asahi Kasei)

Recently, the number of applications of composite materials using foam cores is expanding to reduce weight and increase the stiffness of parts in various industries. However, autoclave methods, such as PCM (Prepreg Compression Molding) and RTM (Resin Transfer Moulding) used for manufacturing composite materials generally require high heat resistance of over 100 °C in the composite process. Therefore, the number of applicable foams is limited, and most of the high-heat-resistant foams are in sheet form, requiring pre-cutting, which leads to high processing costs and poor productivity.

At the JEC World 2025, Asahi Kasei will present Sunforce, a particle beads foam based on the engineering plastic m-PPE (modified polyphenylene ether). This foam features heat resistance, dimensional stability, low water absorption from the modified PPE, in addition to lightweight, thermal insulation, and formability originating from the bead foam. Sunforce beads can be molded by in-mold foaming, utilizing the steam chest molding process. This process in combination with the small-sized beads allows for the medium- to high-volume production of composite core parts with accurate, complex and curved shapes and without the need for additional milling. In addition, m-PPE resin features a low-water absorption. Sunforce can be used as foam core or sandwich material for composite applications in the medical, industrial, aeronautical, or sports industry.

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