Compression Molding

How Molded Nonwovens are Pressed Into Functional 3D Shapes Using Heat and Pressure

The Compression Molding Process for Nonwoven Materials

In the compression molding of nonwovens, the material is first heated in a contact heater to bring it into a malleable state. The nonwoven is then transferred to a special mold and compacted under pressure and cooling until it reaches the desired shape and strength. This process allows nonwovens to be molded into almost any shape without compromising their structural integrity. The result is customized products that are both functional and aesthetically pleasing.

Efficient Structure of the Formfleece Process

We produce a wide variety of cases and molded parts with several molding presses. Pressing systems with very large formats and a high pressing force mean that we are equipped to meet the high demands of our customers. We require individual tools for compression molding, but these can be manufactured cost-effectively compared to other production processes. By separating the heating and forming/cooling stations, we achieve short cycle times. In this respect, the cooperation between heating and press module enables us to optimize throughput times. This enables efficient series production for medium-sized batches.

Get to Know the Compression Molding Process in Our Video

  • Illustration einer Formpressmaschine

  • Flexible Design Through Segmented Pressing

    Through targeted heating and the appropriate tools, we can press nonwovens completely or only partially. Therefore it is possible – especially when using polyester nonwovens – to integrate acoustically effective cushions or pads into an otherwise rigid component and to create flexible end products.

  • Creative Decors Through Lamination

    Using the one-shot process, nonwovens can be laminated process with foil or textile decor material during the forming. This results in greater flexibility in the selection of surfaces decorations and colors.

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Ein Formpresse bei der Herstellung von Formteilen aus Vlies.

Technical Details of Our Molded Fleece Processing

Machine Types for Pressing Fleece

Automated compression molding machines for fleece materials

Work Surface of the Machines

Up to 2000 x 1000 mm (several small formats)

Fleece Materials We Process

We mainly process nonwoven materials in the pressing process. There is a wide variety of materials available here: whether bio-based, degradable or recyclable - we will find the right solution for your project. In our blog post on the different types of nonwoven, we compare their advantages and disadvantages.

Polyester Formfleece: A Recycled Mono-material

Polyester fleece can also be of recycled origin and, as a mono-material, is very easy to recycle. It is ideal for the compression molding of 3D molded parts and is available in many colors and finishes. More about polyester fleece.

Natural Fiber Formfleece: Degradable Hemp Fleece

Natural fiber nonwoven consists of European hemp and a degradable thermoplastic matrix fiber. This means that natural fiber nonwoven is biodegradable and has a strong, natural appearance. More about natural fiber fleece.

Upcycling Textile Formfleece: Used Clothing for 3D Molded Parts

Nowadays, old clothes have hardly any purpose and end up in landfills and incinerators. We want to put them to better use and give them a new life as high-quality 3D molded parts. More about upcycling textile fleece.

  • Gestapelte Teile aus gepresstem Formfleece, die als akustische Wandelemente genutzt werden.
  • Das Innere einer Formpresse mit Fokus auf das Aluminiumwerkzeug, das eine Vliesplatte presst.
  • Eine Nahaufnahme einer hellgrauen gepressten Vliesplatte.
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Fine Tuning for an Exact Fleece Shaped Part

In the molding process, we can calibrate the pressing force, heating time and press length with a vast variety of options. It allows the parts to have flexible 3D shapes and to achieve a desired strength of the component. Haptics and material properties can additionally be influenced.

  • Cutting

    Depending on the geometry, it is possible to punch the molded parts subsequently or cut them through waterjet cutting. Machining with saws or milling is also possible.

  • Edge Finish

    Visible edges can be bordered with different colored bands. Profiles can also be attached by sticking or sewing.

  • Assembly

    The parts can be assembled in a variety of ways, for example using zippers, add-on elements and push buttons, or by gluing parts together.

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Frequently Asked Questions About 3D Compression Molding

Molds

Tools are always milled from aluminum. For prototypes we mostly use wood or Ureol.

Quantities

The compression molding process is suitable for medium series. It usually makes sense from about 1,000 parts over its runtime.

Temperatures

Depending on the material, the temperature is approx. 130°-220°. This is also determined by the thickness, properties and desired properties of the final part.

Development time

Generally, it takes 4 to 6 weeks after the drawings are finalized to create a prototype. A series tool takes between 8-10 weeks, so that the first series production can usually start after 8 weeks.

Stability

Depending on how much the fleece is pressed, different strengths can be achieved. The material can be pressed very hard to cover certain functional areas of application or very soft to improve acoustic effectiveness.

Strenght

As the nonwoven material can have different thicknesses in its raw state, the thickness of the end products is also variable. We can press the fleece with millimeter precision.

Color combinations

It is possible to use different colors in one product and press them in one step.

Individual designs

The individual production of tools means that unique designs, the application of textures or similar techniques are also possible.

Material properties

Molded fleece is an excellent alternative to conventional materials such as plastic or wood. Nonwovens are characterized by their low weight, the UV resistance of their colors, their exceptional texture and feel and, last but not least, their sound-absorbing qualities.

Industries

Formfleece is suitable for applications in a wide range of industries. We manufacture it for the furniture industry, the automotive industry, the case industry and other technical industries.

Recycling

We primarily use recycled nonwovens or bio-based nonwovens and return this material to its raw state in a closed cycle after the product has completed its life cycle. This means that the raw material can be reused several times without any loss of quality and without harming the environment.