Structural foam inserts

has developed a structural foam inserts (SFIs) process that’s already found a home in the automobile industry.

"SFIs offer customers the benefit of combining traditional Betafoam polyurethane foam solutions with the convenience of easy to install pre-formed parts," said Paul Juras, Market Development Manager for Dow Automotive.

Here’s how it works: first, Dow’s ‘Betafoam’ structural polyurethane foam is moulded into pre-formed geometries. Next, when cured, it’s overmoulded with Dow’s ‘Betamate’ structural adhesive using a Dow Automotive proprietary resin transfer moulding process.

The SFIs nests into sheet metal cavities and the epoxy adhesive expands and rigidly bonds the foam parts to the surrounding steel structure during plant bake processes.

Dow says that the SFIs are currently in use on several GM vehicles including in the upper centre pillar area of the 2005 Buick LaCrosse.