Several German universities and companies are working on the SamPa technology project as part of the FOREL research platform. The project combines particle foaming and injection molding processes to form a new integral processing technology for manufacturing structural components used in electric vehicles.

The research partners leveraged seven molding tools to implement innovative concepts for functionalizing particle foams - and demonstrated their results with a multi-part door paneling concept. To assemble the components, plastic and metal inserts adapted to the load were foamed into the components. Made of expanded polypropylene (EPP), the door’s base frame provides sufficient space for the display, mini PC, lighting and cables. Polyurethane foaming was also successfully demonstrated in a concept for the door’s exterior surface. The partners are convinced that the new process has great potential in vehicle construction